Week 1 Flashcards
Pasteurization effect occurs in temps at or above what?
120F / 49C
Complete and adequate pasteurization requires what?
Minimum of 5min at 140F / 60C
Define a pasteurization unit
Pasteurization Unit = 1 min @ 60C
PUs increase linearly by time and logarithmically by temp
Name the basic stages of a beer packaging line.
- Depalletizing
- Rinser (or bottle washer if returnable bottle line)
- Filler
- Tunnel pasteurizer (unless sterile fill)
- Labeler (if bottle line)
- Packer
- Palletizer
What are the three basic challenges in beer packaging?
Quality
Package appeal and appearance
Cost Effectiveness
What possible quality problems can be associated with the container?
- Dimensional consistency - cartons must feed into and through machine, at design speed, without disruption
- Material consistency - material gauge and flexibility held to close tolerances to allow for high speed feeding
- Surface characteristics - including “slip angle” - angle at which carton will slide off of others
- Carton scoring - must flex or bend, must be consistent and adequate
Why is sanitation a concern in packaging?
Requires the same level of commitment as brewery area
**sanitation is both a quality issue and a performance issue in packaging
Necessary to maintain quality of product on product contact surfaces
What is the main cost center of a packaging brewery?
-Typically requires 60% initial capital
- Commands 70% of “follow-on” capital
- commands 80% maintenance budget
Packaging materials alone usually cost more than total brewing operations
What is the impact of material consistency on packaging line performance?
Automated controls cannot generally accommodate material variability. Variability often needs manual intervention and thus limits high-speed capability of the line
Reason for glass end bottle treatment?
Improve hardness (reduce breakage)
“Scuffing” protection
Name 3 advantages of glass bottles
- Flavor inert
- gas impermeable
- consistent shape (not with old molds) = well known handling characteristics,
- recyclable
Three advantages of PET?
Light
Unbreakable
Simple alteration of bottle designs
Is PET a hydrophobic material?
No, it is hydroscopic and will suck up water and impact ability to form
AA in PET bottles
AA can be formed during heating (260-280C) - during the injection moulding process.
Higher moisture content also creates higher AA
Higher temps and longer time of PET in hot fluid condition
Formed in pre-form manufacturing process
Permeability of PET?
Gases, water vapor and flavors
Permeability of CO2 = 5 times more than that for O2
Minimum CO2 reduction and O2 intake for PET bottles for beer during shelf-life?
Max reduction of CO2 = <15%
Max intake of O2 = 1mg/l
What are a type I and type II statistical error?
Type I: concluding that samples are different when they are not (producer risk?)
Type II: missing a difference that is there (consumer risk)
How much of a normal population falls within +- 3õ of the mean?
Virtually all of it
What is a good measure of a ”typical” value from a sample of well-behaved data?
X-bar or u
What does it mean if one of your QC samples falls outside of the upper control limit on your X-bar Chart?
Means that there is an assignable cause and you should go and find and fix it
The speed rating of the filling process usually determines what?
The output rating of the entire packaging line - need to run 90-95%
Torque rating for a twist top crown?
8-12
Name 3 critical control factors for effective beer delivery into the bottle/can
?????
Fill volume
In-package oxygen
Carbonation level
Appearance
The two primary sources of in-package oxygen within the filling process are…
Absorption - dissolved O2 into the liquid
Entrainment - air which is drawn into the package. This is the most common cause of elevated in-package O2
Highest TPO (total package oxygen) is what?
No more than 20ppb DO
Foam rate stability in bottle & can filling is achieved by controlling what three factors?
Delivery temp - cold and consistent
Delivery pressure - maintain above beers CO2 saturation pressure throughout delivery system
Controlling turbulence within the delivery line - turbulence from bends, changes in pipe diameter. Higher velocities exaggerate these effects
Ideal delivery pressure of beer into bowl filler is…
Around 2 bar (30psi) above the bowl operating pressure
How to control oxygen in headspace of filler bowl?
Purge system with cold, deaerated water initially and then, during filling, purged gas from the containers are vented into headspace of bowl and should be continually infused with fresh CO2 and vented from another point
The two primary purposes of the bowl level and pressure controls are:
Ensure a smooth, adequate supply of beer to filling valve stations
Maintain the desired CO2 counter pressure on the beer throughout the filling process
Requirements for effective beer level control in the bowl…
Incoming beer pressure sufficient to over come pressure during operation - rec at least 1 bar above bowl pressure
Smooth, well tuned operation - no surging or valve hunting
Adequate response time of control components to avoid low liquid level at start-up or overflow during shut down
What is a jetter?
What is a bubble breaker?
Between the filling station and the crowning station, the bottle will pass beneath a “jetter” which is a high velocity (45-150psi)- low volume stream of potable water (some use steam).
This agitates the surface of the beer and causes a quick foam rise
The rising foam displaces the air in the bottle as the crown is placed onto the bottle. Cap on foam.
For cans, a station - bubble breaker - will blow low pressure, high volume of CO2 across the liquid as the lid is placed on and goes to the seamer
A properly operating can/bottle filling process is defined by the following 5 things:
Consistent fill levels
Consistently low (“acceptable”) levels (what’s the average?) of in-package air content (TPO less than 20ppb)
Consistent CO2 vol per container
Low (“acceptable”) beer losses (0.1%-0.2% acceptable)
A consistent and efficient process which operates at rated speed
Name the advantages of the short tube filling process
Often incorporates a pre-evacuation stage prior to fill
Simple procedure to alter fill levels (adjust to switch out tubes with different lengths
Faster filler speeds
Describe characteristics of long tube filler
Utilizes a SS tube to deliver liquid into the container
Excellent fill level consistency
Smooth and controlled liquid fill with min agitation or contact with air in the container
Less critical of beer condition at entry to the filler
What are the three advantages of packaging beer in cans?
Totally prevents contact with light
Allows no measurable ingress of oxygen
Allows no measurable egress of CO2
What is the purpose of the first seaming operation in canning
The first operation roll forms the “loose” seam by compressing the cover curl on the lid and forming it around the flange at the top of the can to create the loose seam.
It is critical that this operation forms the proper countersink depth and seam thickness
What is meant by the term “seam overlap?”
Seam overlap is the overlap between the cover hook and body hook in the final seam
Why is maintenance critical to seaming performance?
It is a precision process that requires precise and repeatable machinery
Very little wear on components can be tolerated
Machine setup and adjustment is critical as well as scheduled maintenance
