VBL Brewing Microbiology Workshop v2 2011

Brewing Microbiology
Practical Knowledge &

Application by TPM methodology
(non-yeast)
Le Quang Hai
VBL Group - Technological Controller
VBL Microbiology Workshop

2009 Feb
Chapter 1
Brewing microbiology
Feb 2009
Le Quang Hai - VBL Technological Controller
Micro-organisms
During production of beer, several micro-organisms are likely to grow
because of nutrient-rich environment (sugar, amino acid, phosphate,
sulphate, oxygen, vitamins, minerals) and suitable conditions
(temperature, time, pH)
However, characteristics of beer alcohol, CO2, SO2, pH reduce the
range of organisms. Examples:
Lactobacillus (L.brevis, L.lindneri, L.brevisimilis, L.frigidus, L.coryniformis,
L.Casei)
Pectinatus cerevisiiphilus
Feb 2009
Microbiological defect and off-flavor

Sensation
Bacterium
Phenolic, Smoke, DMS
Enterobacter
- Aerogenes
- Klepsiella
Wort, Fermentation
DMS, H2S
Flavobacterium
- (Obesum)
Wort
Celery
Aerobacter
Escherichia
Fermentation
Sweat, Cheese, Iso-valeric acid
Megasphera
Wort, Fermentation
Milky, Vingar, Propionic acid
Pectinatus
Cerevisiiphilus
Wort, Beer
Rotten apple, H2S
Zymomonas
Beer
Vinegar
Acetobacter
Wort, Beer
Diacetyl, Sour
Pediococcus
Lactobacillus
Buttery, Cheese, Rancid
Clostridium
Adjuncts, Wort
Apple, Vinegar
Acetomonas /
Gluconobacter
Beer
Phenolic, Smoke
wild yeast
Anise
wild yeast
Feb 2009
O2
_
or trace of oxygen is
required
_
_
Process stage
Wort, Fermentation, Beer
Wort, Fermentation
Wort, Fermentation
4
Micro-organisms (ex: flourescence method)
Feb 2009
Reclamation of beer spoilage in Germany
Feb 2009
Micro-organism type
With requirement of Oxygen
Group
Aerobic Env
Anaerobic Env
O2 effect
Obligate Aerobe
Growth
No growth
Use O2 as a food electron acceptor in

aerobic respiration
Microaerophil
Growth if O2
level not to
high
No growth
Required O2 < 0.2 atm
Obligate anaerobe
No growth
Growth
O2 is a toxic substance
Facultative aerobe /
anaerobe
Growth
Growth
Not require O2 to growth but utilize it when

available
Aerotolerant anaerobe
Growth
Growth
Exclusively anaerobic (fermentative) type

of metabolism but not insensitive to the
presence of O2. Not required O2 and not
utilize it
Organism grows from 1 108 times in less than 9 hours when circumstances
are ideal
Feb 2009
Micro-organism type (cont)

With temperature
Psychrophiles (cold)
: 0 300C
Mesophiles (medium)
: 20 500C
Thermophiles (hot)
: 40 700C
With acid degree or pH value

If 6 < pH < 8: optimum for micro-organisms
If pH < 4: growth of most bacteria limited (except for acid tolerant bacteria
With water and other nutrient (sugar, minerals)

Osmophilous: growth in medium wealthy on sugar
Xerophilous: growth in medium poor in water
Halophilous: growth in medium wealthy on salt
Bacteria growth is limited with less water
Feb 2009
Prevention of infection
Sanitary mindset of personel
Good housekeeping
Hygiene design of equipment
Hygiene maintenance
Efficiency CIP (cleaning and disinfection)

Monitoring through reliable microbiological control procedures
Feb 2009
Chapter 2
Biofouling and Biofilm
Source:
IWW Water Center, Mulheim an der Ruhr, Duisburg Essen University
Markus Timke, Analysis of Biofilm communities in Breweries, Biologies/Chemie der Universitat Osnabruck
Feb 2009
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What are bio-fouling and biofilm

Fouling: undesired deposit of materials on surface
Organic: deposit of fat, oil, protein
Inorganic: precipitation of inorganic crystal or scaling
Particle: silt, clay, humid particles
Bio-fouling: undesired deposit and growth of microorganisms on

surface particles (interface) which can multiply on the expense of
nutrient
Biofilm: is a matrix of extracellular polymeric substance (EPS),
associated with working materials, corrosion products, debris, soil,
particles, etc
Biofilm includes films on surface, flocs, (floating biofilms), mat and
sludge all kinds of cell in matrix
Feb 2009
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Examples of biofouling, biofilm
Feb 2009
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Examples of biofouling, biofilm (cont)
Feb 2009
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Examples of biofouling, biofilm (cont)
Feb 2009
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Affection of biofoul & biofilm

Water quality: contamination by releasing micro-organisms
Health: release of pathogens in water

Hydrodynamic parameters: clogging, friction & hydraulic resistance
Material: covering surface, changing surface properties, enhancing
microbial influenced-corrosion
Feb 2009
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EPS: house of the cells

Has a composition of extracellular polymeric substance:
polysaccharides, proteins, nucleic acids, forming hydrogels (> 95%
water) of microbial origin
Is an attachment of cells and of entire biofilm to surface
Is the cohesion in microbial aggregation
Is filling and forming the space between the cells, shape the threedimensional biofilm structure
Helps immobizing cells, allowing long-term syngenesis interactions
Feb 2009
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Step formation of biofilm
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EPS and micro-organisms infection
Feb 2009
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Where are biofilms in water system
Feb 2009
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Mushroom model of biofilm
Feb 2009
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Mushroom model of biofilm (cont)
Feb 2009
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Principles to reduce biofoul & biofilm

Nature of live: brewery has to learn to live with biofoul / bioflim and
keep them under control elimination of their affection
Detection: the growth of biofoul / biofilm and their affection
Defining detection parameters (cell/cm2, CFU/cm2, biofilm thickness),
points, sampling points to monitor their growth, affection
Setting up a monitoring system: crucial for timely detection of biofilms and
countermeasure optimization
Tolerance of biofoul/biofilm growth: applying risk management in terms

of Haccp and product quality to set up max tolerance. Either:
Thickness of biofoul / biofilm
Micro-organism plate count on suitable media
Cleaning: is more important than killing biofilm organisms. Setting up a

suitable cleaning regime with consideration of affection and cost
Prevention: where possible, biofilm management is done by nutrient
limitation (nutrients are potential biomass)
Feb 2009
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Biofilm growth and threshold

Monitoring biofilm growth on time via quick testing method (ATP swab)
or Onvida sensor
Pain Threshold is defined by user where the affection of biofoul, biofilm
pathogenic and product quality - is measurable
Feb 2009
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Method to detect & monitor biofilm
Feb 2009
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Killing vs Removal biofilm

Killing does not necessary to remove biomass, so dead biomass can
still cause problems for process, product and health (head exchanger,
membranes, process water)
Disinfection means inactivation of micro-organisms and this frequent
job creates additional cost but not to sustainable solution
Feb 2009
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Chapter 3
Cleaning & Disinfection principles
Source:
HeiQ
Paul Wood APB Microbiology Workshop
Stijn Van Liefferinge, C&D Sopura SA
DiverseyLever, Basic principle of CIP& Application
John David Cluett, Cleanability of Stainless steel surface, Rank Afrikaans University, USA
Feb 2009
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Cleaning principles
Feb 2009
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What to clean: soil

To eliminate impurity of solution called soil
To disinfect a surface effectively, elimination of soil must be completed

first
Soil is any undesired matter on surface including product whether
containing micro-organism or not
Sources of soil:
Residues of products (beer extracts, fats, lipids, proteins )
Residues of water-soluble (salt, sugars) and acid-soluble products (calcium
precipitates, dissolved inorganic)
Residues of water/acid-non-soluble (yeast)
Bio-film (bacteria, mould)
Residues / carry-over matters from cleaning and disinfection products
Contaminated by external environment (dust)

Feb 2009
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Cleaning of soil - Function

Function of cleaning soil: is to remove/eliminate soil without leaving
residues by either one or combination of actions:
Dissolving / emulsifying
Chemical reaction
Physical: mechanical, thermal
An effective cleaning of soil depends on soil characteristics, nature of

surface and selection of
Right physical actions
Right cleaning product
Sufficient activity of cleaning product (concentration, activity level)
Right cleaning procedure (regime)
Right cleaning tools/equipment
Right process control conditions
Feb 2009
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Cleaning soil
Function: cleaning of soil is achieved by one / combination of energies:
Mechanical
Liquid rinsing flow (hl/h respective with designed flow Re)
Pressure flow impact (bar)
Brushing (kg/cm2, frequency time/s), stirring (rpm)
Thermal: only effective when it goes with time and limited by machine
component and economy reasons (0C)
Chemical
Removal of soil without leaving residues
Concentration, frequency and contact time (economy use)
Environmental impact
Affection on material being cleaned (machine component, pipe)
Time is combined with energy to have necessary cleaning but

sometimes a waste and limited by product process flow
Feb 2009
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Cleaning product - Function

Function of soil cleaning is achieved by the help of a cleaning product
or also called carrying-product
Without cleaning product, soil cannot be removed from surface/system
Function of cleaning product: is to
Set a complete and full contact between soil, surface and product by
wetting, lowering surface tension
Eliminate adhesion of soil on surface by rinsing
Reduce soils gravity by dispersing soil in small particles
Carry soil particles in product till it is discharged to sewer by dissolving or
emulsifying and suspending them - keep floating detached particles to
prevent precipitation
Sequestering: eliminate / prevent the fall out water hardness salts
Feb 2009
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Cleaning products
Surfactants: makes a link between organic matter and water
Anionic
Cationic
Non-ionic
Amphoteric
Wetting / Rinsing agent: reduces surface tension of water only

Dispersing agent: keeps removed soil in suspension avoids the
formation of soil floc
Sequestering agent: binds itself to something else
Alkaline:
EDTA (Ethylene Diamine Tetra Acetic Acid) can dissolve scale binding with
calcium and break it up when rinsing
Phosphonates
Na5P3O10
Gluconates
Feb 2009
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Cleaning products
Dissolving / Reaction agent
Acids:
H2SO4
H3PO4
HNO3
Sulphamic acid
Organic acid like acetic acid
Alkaline:
Strong alkaline: caustic soda
Alkaline salts:
Metalisicates,
Na3PO4
Na2CO3
Oxidization agent
Feb 2009
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Wetting & surface tension

Surface tension is the result of intermolecular attractive force which
assures the cohesion of molecules
Both cleaning product and soil have surface tension
Water has high surface tension > bad wetting action
Wetting
and low
surface
tension
Feb 2009
Wetting
and low
surface
tension
No wetting
and high
surface
tension
No wetting
and high
surface
tension
36
Surfactants
Feb 2009
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Sequestrant
Feb 2009
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Physical form of soil

Physical form of soil on surface and its adhesion on surface
Loose, dry soil on surface:
Priority: mechanical (liquid flow)
Addition: mechanical (pressure impact), thermal, chemical (dissolving /
emulsifying)
Sticky soil in liquid or solid form (yeast stone, protein):

Priority: mechanical (pressure impact, liquid flow) + chemical (reaction,
dissolving/emulsifying)
Addition: thermal
Solidified soil (dried yeast stone, beer/extract stone, scale)

Priority: chemical (reaction, dissolving/emulsifying) + mechanical (liquid flow,
pressure impact)
Addition: thermal
Feb 2009
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Composition of soil
Composition of soil and removal method
Organic: containing carbon element in molecule
Alkali dissolvable organic matters like caustic soda in environment of non-CO2
gas
Acid dissolvable organic matter like phosphoric acid
Inorganic: not containing carbon element (Ca++, Mg++)

Acid dissolvable inorganic matter
Combination of organic and inorganic
Feb 2009
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Practical soil in brewery
Feb 2009
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Practical soil in brewery (cont)
Feb 2009
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Nature of surface
Surface roughness is evaluated via parameter Ra (m) peak-tovalley height. The less the better. Stainless steel fermentation tank: Ra
0.8 m
Other parameters: max Ra, waviness Wt, total depth Pt, spacing Nr
Feb 2009
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Mechanical rinsing flow - pipeline

Fluid movement: Reynolds index
Reynolds index for pipeline: Re = *r*v/n

: density of chemical product (g/cm3)
v: average flow velocity (cm/s)
r: pipe radius (cm)
n: dynamic viscosity of liquid (g/cm*s)
Flow during cleaning of pipe line at internal surface

Re < 2,000
: laminar flow
2,000 < Re < 3,000
: transition flow
Re > 3,000
: turbulent flow
Real turbulent flow starts only at Re > 10,000
Internal pipe surface and welding line are failure of Re
Feb 2009
51
Mechanical rinsing flow pipeline (cont)

Rule of thumb for liquid flow respectively with Re > 3,000
Cold cleaning (ambient temperature): velocity >< pipe diameter
For pipe diameter 50 mm, a flow > 3.5 m/s must be reached
For pipe diameter > 50 100 mm, a flow > 2 m/s must be reached
For pipe diameter > 100 mm, a flow > 1 m/s must be reached
Hot cleaning (80 850C): velocity 1 1.5 m/s is sufficient
Flow rate is calculated from pipe diameter and velocity

If velocity is lower than above, cleaning is not effective, i.e. presence of
soil residues after cleaning
If velocity is higher than above, there is no improvement of cleaning but
a risk of water hammer, damage to pipe work and fittings
If velocity is as above but soil residues are found at final rinse, look at
effectiveness of other cleaning actions and energies
Feb 2009
52
Mechanical rinsing flow pipeline (cont)

Flow rate in liter per minute
Feb 2009
53
Mechanical rinsing flow - tank

Reynolds index for tank: Re = mF/n
mF: mass flow of medium film a meter tank width (circumference)
n: dynamic viscosity of liquid (g/cm*s)
Flow during cleaning internal surface of tank

Lamination film 200 < Re < 500
: 0.5 1.5 L/min/m2
Turbulent film Re > 3,000
: 1.4 3.3 L/min/m2
As experiment, at Re > 3000 and Ra = 0.8 stainless steel tank, the flow
speed on internal tank surface is about 0.022 0.025 m/s
Extra mechanical effect: pulse dwell with fixed spay ball
Feb 2009
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Mechanical rinsing flow Plate Heat Exchanger

Rule of thumb, cleaning of heat exchanger requires a detergent flow
rate which is 20 30% higher than the product flow rate
For high soil content product like wort, cleaning rinsing flow of PHE is
in reverse direction of product flow, i.e. cleaning product going from
outlet of PHE to discharge at inlet of PHE
Feb 2009
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Mechanical flow pressure impact

Flow pressure impact is critical in cleaning of soil in tank. All tank
cleanings are done by spray device system
Spray ball inlet flow pressure is very critical
Static spray head
: 1 2.5 bars
Rotary spray ball / disk
: 5 8 bars
Too little pressure: tank wall is not reached, less flow pressure impact
to remove sticky/solidified soil, not enough rinsing flow for tank
Too high pressure: reduces effectiveness of rinsing flow
Feb 2009
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Thermal of cleaning flow

Temperature is defined according to
Cleaning product used (supplier spec)
Customer specification (machine, system, fittings, sealant)
Soils characteristics
Material surface to be cleaned
Not always higher temperature of cleaning fluid, lower cleaning time!!
Feb 2009
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Disinfection principles
Feb 2009
58
What to disinfect: micro-organisms

Function of disinfection: destroying of beer spoiling and not-beer
spoiling micro-organisms to an acceptable level
Micro-organisms can be :
Pathogenic
Harmful
Troublesome
to health or to the quality of products

Bacterial spores are usually not killed and difficult to be killed
Micro-organisms are destroyed by one or combination of methods

Chemical disinfectants
Physical: UV, heat
Sterilization destroys all forms of live
Feb 2009
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Source of micro-infection
Source of contamination:
Production process
Apparatus having dead ends
Chinks, fittings, couplings
Surface, material, system cavities
Open vessels (air suction)

Residues from previous process
Pre-run / Post run
CIP process
Contaminated final rinse water
Bio-film
Others
Man: flora from hand, breath, skin, clothes, production tools
Insects, dust
Feb 2009
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Disinfection
An effectiveness of disinfection depends on:
Type of micro-infection, i.e. micro-organism species
Level of micro-infection, i.e. number of micro-organisms
Type of disinfection method, e.g. disinfectants
Concentration of disinfection dose
Type and conditions of surface

Temperature
Movement of liquid
Type and amount of soil residues, dirts
Feb 2009
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Disinfectants
Selection of disinfectant is a consideration of:
Broad spectrum and biodegradability, especially spore forming
Minimum influence of at application conditions: pH, low temperature, presence
of protein
Neutralization by CO2
Composition should not changed or reduced by carrier (ex water hardness)
Food and health safety: no smell, taste / colour or harmful to man
No influence on material / surface (ex: corrosion)
Easily rinse-able by water (ex residue after cleaning)
Environment friendly and local legal compliance
Technological useful (contact/exposure time, installation)

Recoverable
Cost (i.e. consumption, price)
Disinfectants can be not stable at storage (both concentrated solution

and working solution)
Feb 2009
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Disinfectants (cont)
Common disinfectants:
Chlorine (NaOCl and ClO2)
Iodophores
Halogenated acetic acid ester
Halogen carbon acid
Peroxydes
Gluteralhehyde
Quaternary ammonium compounds (QAC)
Amphoterics
Salicylates
Feb 2009
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Chapter 4
Cleaning & Disinfection System & Procedure (Regime)
Source:
HeiQ
Stijn Van Liefferinge Sopura SA
Feb 2009
64
Control and reduction of soil load

CIP is a cleaning system integrated into production process can be
manually controlled or completely automated
03 type of CIP programs:
Regular Cleaning and Disinfection (C&D)
Disinfection only
Occasional Cleaning & Disinfection
TPM 1st priority: Regular CIP program is set up and controlled for a
standard soil load and micro-infection level and routes. It is effective
when
Soil type and load level (thickness) is controlled (what and how much)
Soil deposited location is controlled (where)
CIP program conditions are controlled
TPM 2nd priority: Less soil load is on surface and system, less
cleaning activities (procedure) is required, i.e. lower cost, higher
productivity
Feb 2009
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Control and reduction of soil (cont)

Control of soil load - examples
Scheduled inspection of tank before / after CIP
No violent fermentation, no overfoam at FST
Cleaning within time tolerance after emptying
Contamination of recovery cleaning chemical products
Reduction of soil load - examples

Settlement and draining caustic in washer
Mess-filtration of caustic at washer
Pre-rinsing yeast harvest on pipe before CIP
Keeping system cleaned and dry for a period of stop time
Soil development conditions are present and monitored so that

occasional CIP is applied
Feb 2009
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Standard CIP recovery & circulation
Feb 2009
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Standard CIP program Functions of step

Pre-rinse: reducing of soil to a level where the designed CIP regime
(procedure) is applied, normally by water rinse or recuperation caustic
Medium change: obtaining right conc of cleaning chemical, normally in
CIP supply pipe
Rinse: eliminating soil by hot/cold caustic, acid agent is used in some
conditions (under CO2 pressure)
Intermediate rinse: recuperating and reducing conc of cleaning
chemical to an acceptable level
Medium change: obtaining right conc of disinfection chemical, normally
in CIP supply pipe
Disinfection: destroying micro-organisms
Medium change: recuperating and reducing conc of disinfectant to an
acceptable level
Final rinse: eliminating disinfectant residues before re-using by
disinfected water
Feb 2009
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Example of a CIP program
InFlow
Steps
Group 2
Steps
Object
Fermenter (Vertical)
Fresh
Caustic pulses
Fermenting and/or Storage Tank
Recup
Water rinse
Rest Beer Tank
Recup
Acid circulation
Unfiltered Beer Buffer Tank
Recup
Water rinse
(Waste Yeast Tank, see remarks)
Recup
Disinfectant circulation
Foam catcher
Fresh
Water rinse
Feb 2009
OutFlow/Recup. Parameters
T
Strength
Duration
Rest
Pulses
to drain
Ambient
1% w/v
1 min
10 min
to drain
Ambient
1 min
2 min
3 min
1 min
1 min
2 min
to Group 1 and 2 Ambient by supplier
3 min
1 min
to Group 1 and 2 Ambient
1 min
2 min
to Group 1 and 2 Ambient by supplier

to drain
Ambient
69
Conditions of CIP: run & change steps

Pre-rinse: one / combination of either some or all
Soil load (thickness): visual assessment before and after pre-rinsing majority of
sticky soil
Circle count: pre-rinsing volume and total volume of all circles; Or: pre-rinsing time /
circle and total time of all circles
Circle ends: Empty signal if applicable (LAL)
Number of circles
Pressure of flow on CIP supply pipe (after pump) or pipe head to spray ball
Flow rate of CIP supply pipe (after pump)
Medium change to rinse: one / combination of either some or all

Concentration / conductivity at pipe head to spray ball or sometimes at return pipe to
drain
Medium volume at desired point
Time to reach the concentration / conductivity
Opening time of draining valve
Feb 2009
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(cont)
Rinse: one / combination of either some or all
Soil load at final rinse: visual assessment (color), chamber count of soil (soil
density), identification of soil
Circle starts: temperature, conc/conductivity = designed value
Hot cleaning: temperature after PHE, temperature at return pipe (recovery)
Conc/cond at pipe head to spray ball (rinse to drain) or at return pipe to drain (recovery)
Circle count: pre-rinsing volume and total volume of all circles; Or: pre-rinsing time /
circle and total time of all circles
Number of circles
Spray ball: pulse and pause duration
CIP return pump: run / stop duration
Chemical contamination load after rinse (COD, turbidity, EBC, UVA rate): recovery
system

Feb 2009
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(cont)
Final rinse: one / combination of either some or all
Micro-infection: ATP swab, micro analysis of final rinsing sample
Disinfectants/cleaning product infection: smell, concentration, indicator
(phenolphthalein)
Circle count: pre-rinsing volume and total volume of all circles; Or: prerinsing time / circle and total time of all circles
Number of circles
Spray ball: pulse and pause duration
CIP return pump: run / stop duration
Feb 2009
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Volume for a CIP circle

Sufficient fill volume for a C&D circle is important for an effective CIP:
cleaning flow and sometimes soaking
Cleaning product and water consumption is made up on a given CIP
route
A fill volume is about 1.3 calculated volume of pipe route + volume of
chemical thickness on vessel surface (1.5 3.5 L/m2)
Feb 2009
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Chapter 5
Cleaning & Disinfection Agents
Source:
HeiQ
Stijn Van Liefferinge Sopura SA
Paul Wood APB Microbiology workshop
Feb 2009
74
Selection of cleaning products

Factors affecting selection of cleaning products
Nature of soil
Nature of material of unit / system (surface, type of steel, heat stability)
Hardness of material
Temperature
Cleaning method, procedure
CIP equipment / system
Possible danger of product man safety
Influence on product food safety

Biological degradability environment
Cost
Feb 2009
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Application properties of cleaning product
Feb 2009
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Some chemical products ex Sopura

ATR B
Based on phosphoric acid combined with non-foaming non-ionic
biodegradable surfactants
Removal yeast deposit and beer stone on vessel surface under CO2
pressure condition
Caustic Purexol:
Based on sequestrants + KOH + 3g chlorine / 100 g product
Alkaline chlorinated detergent for the simultaneous deep cleaning and
sanitation removal sticky and organic scale (solidified) on surface
Normal application frequency: once 12 18 months
Septacid S
Based on sulphuric acid, bromacetic acid and corrosion inhibitors
Simultaneous cleaning and sanitation with strong bacteriocidal actions on

yeast, both gram positive and negative bacteria
Feb 2009
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Chapter 6
Spray heads
Source:
Sani-matic spray ball
Toftejorg high pressure impact Rotary Jet Head
Feb 2009
78
Static spray head

Static / fixed spray head:
2 types: spray ball and spray disk
Operation pressure: normally low pressure: 1 2 bar
Key parameters of spray ball should obtain to get effective cleaning:
Specific flow rate
Pressure and pressure curves

Connection inner and outer diameter
Spray ball types: 3600, 1800 upward, 1800 downward, 1800 directional bias shot,
2700 upward, 1200 upward
Choice of spray ball types depends on:

Distance of device from walls of tank
Depth of installation
Tank dimension
Type of cleaning product used
Tank use
pump specification
Feb 2009
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Guide line for spray ball

3600: applied for heavily soil or tank with internal devices
1800 upward spray: cleaning top of tank, lower half of tank will be
cleaned from the fluid running down side
1800 down spray: cleaning specific internal instrument or other items
that interfere with cleaning used downstream spraying ball
2700 upward spray: covering more surface and allow direct cleaning
(pressure impact of cleaning product) of more heavily soiled areas,
specially top tank dome, yeast ring.
Bottom center of tank may have outlet valves or other fixtures that do not
require direct exposure to cleaning unit
Feb 2009
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Static spray head pattern
Feb 2009
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Static spray head pattern (cont)
Feb 2009
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Static spray head parameters
Feb 2009
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Static spay ball Installation depth
Feb 2009
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High pressure rotary spray head

High pressure rotary spray head
High pressure: 5 8 bar
Impact throw length is 5 15 meter
Rotary Jet head provides 3600 indexed impact cleaning over a defined
period
Working principle: flow of fluid makes nozzles performs a gear rotation
around vertical and horizontal axes. Normally, 1st cycle nozzle lay out a
coarse pattern on tank surface. A full pattern is reached after 8 cycles
Choice depends on desired jet impact length and flow rate at desired
pressure
Feb 2009
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Rotary spray head pressure curve
Feb 2009
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Pressure loss at spray head

To obtain sufficient pressure at spray ball, pressure at cleaning pump
must be compensated for hydraulic pressure loss (mainly) and other
losses (friction, fittings, bend)
Feb 2009
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Chapter 7
Hygiene Requirements and Standards
Source:
Feb 2009
Heineken Hygienic Design Manual (HeiQ)

Martin Hees, Industry Marketing Food
88
What is hygiene?
Hygiene is
Compliance with all conditions
During design & use of process equipment
To achieve the greatest possible suitability of process
For the purpose to guarantee the highest possible safety for customer of
the product
Functions of hygiene are

Clean-ability of equipment: easily to clean, disinfect protect product from
contamination
Avoidance of penetration of micro-organism from external to system
Inhibition of micro-organism growth in equipment: like dead-ends, gaps,
cracks, bio-film
Suitability of process in compromising hygiene compliance and other

equipment functional requirements (ex OPI)
Feb 2009
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Hygiene zone
Zone B: basic level of hygienic design and maintenance for open
areas like outside buildings, walking way, canteen
Zone M: medium level of hygienic design and maintenance to protect
the interior of food processing equipment during closed processes like
fermentation, filtration
Zone H: high level of hygienic design and maintenance to protect

product contamination during open processing like culturing /
propagation, filling from environment and exterior of equipment
Feb 2009
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What hygiene practices

Hygienic standards should be set for
Suitable selection of equipment and design
Materials and accessories for C&D (ex smooth, no crevices, pits, edges,
blind ends)
Correct construction
Process layout (ex cross contamination)
Process automation of the installation
Effective cleaning is difficult to check but a few below method is used:

Visual inspection before and after cleaning
Water break test (no drops on clean surface)
ATP-free swap test
Feb 2009
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ATP bio-luminescence
ATP is a molecule found in living organisms a main immediate
source of usable energy for all activities of cell
Enzymes called Luciferases that emit light and when ATP is brought
into contact with a combination Luciferin Luciferase, a reaction is taken
place, resulting in production of light from release of Luciferase
The higher contamination, the more ATP present and more light is
produced
Feb 2009
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ATP-free swab
ATP is practically used to evaluate the effective cleaning level instead
of waiting for 3 5 days period where incubation of samples required
How ATP-free swab test works:
ATP swabs are pre-moistened with agents that help to lift soil off surface
After taking sample with the swab, it pushes into tube, is shaken and finally
into illuminometer
Clean sample gives low light level
Dirty level gives high light level. The measure is made in RLU (Relative
Light Unit)
Normally RLU > 100, the surface is not hygiene
Feb 2009
93
Application areas of ATP in a brewery
Feb 2009
94
Application areas of ATP in a brewery (cont)
Feb 2009
95
ATP test example in a brewery
Feb 2009
96
Hygiene in piping, fittings, connections
Feb 2009
97

(cont)
Feb 2009
98

(cont)
Feb 2009
99

(cont)
Feb 2009
100

(cont)
Feb 2009
101

(cont)
Feb 2009
102

(cont)
Feb 2009
103

(cont)
Feb 2009
104
Hygiene in product contact surface
Feb 2009
105
Hygiene in product contact surface (cont)
Feb 2009
106
Hygiene in product contact surface (cont)
Feb 2009
107
Hygiene in accessories (cont)
Feb 2009
108
Feb 2009
109
Feb 2009
110
Feb 2009
111
Hygiene in process equipment (cont)
Feb 2009
112
Feb 2009
113
Feb 2009
114
Feb 2009
115
Feb 2009
116
Hygiene in fittings, connections
Feb 2009
117
Hygienic standards - others

Other hygienic standards are reference in Heineken Hygienic Design
Manual for:
Materials: plastic, elastics, adhesives, stainless steel
Piping system, tees, flanges, gasket, coupling, hosing,
Valves
Other accessories
Heat exchanger
Pump
Process equipment: spray ball, drive shaft and bearing,
Hygiene standards for high risk local machine cleaning is set up by

brewery
Haccp (Iso 22000) requires food safety risk analysis, pre-requisitition
program and verification of risks and control plan
Feb 2009
118
Hygiene audit
After standards available, Hygiene is maintained by schedule Hygiene
Audit by qualified staff
Hygiene Audit is a mandatory requirement of brewery operation
Feb 2009
119
Chapter 8
Disinfection by UV Light
Source:
Feb 2009
UV Wikipedia encyclopedia
American Water Works Association
120
UV Light Application
UV-C 265 nm is germicidal, (1) di-merizes on ADN and inhibits bacteria
to replicate molecule ADN, (2) produces a condense ozone
environment (air)
Germicidal effectiveness is depended type of bacteria and UV dosage
(Ws/m2) at the application point
Each bacterium has different UV resistance: protozoan cyst > bacteria

spore > viruses > vegetative bacteria
UV dosage = UV intensity W/cm2 * Exposure time t (seconds)
UV intensity = UV intensity of Lamps * number of Lamps * Intensity
Factor / Transmission Loss
Feb 2009
121
UV Intensity
In air, UV transmission = 100% at a distance of 1 meter to application
point. The closer the stronger and vice versa (table)
In distilled purifying water, UV transmission = 100% at a distance of 10
mm to application point
UV intensity sensor provides only means of ensuring that adequate
disinfection
Ex: 04 lamps of 66 W/m2 each, reactor: 70 L, water flow: 320 L/min,
T10 = 0.95
Feb 2009
122
Conditions of UV transmission
Water quality factors
Shielding caused by suspension solids
UV light scattering by colloidal solids
UV absorbance by dissolved organics (w
Quartz sleeve foul by inorganic constituents (Ca, Mg, Al, Fe, Mn,
Quartz sleeve transmission ability (colorization of quartz over time)
Water quality (color, air bubble, other factors affecting transmission)
UV lamp low-pressure (LP)

Giving optimum germicidal wave length 260 nm monochromatic
Optimum lamp operating temperature
Lamp age and spectral shift
Feb 2009
123
Conditions of UV transmission
Reactor
Internal chamber surface reflecting capability
UV dose delivered is path-dependent
UV sensor
Number of sensors and placing them at optimum positions
Routine check with reference sensor
Factory check to control linearity and drifting
Sensor window cleaning
Feb 2009
124
UV Reactor monitoring
As the minimum
UV intensity by sensor
Water flow rate
Lamp outage
In addition
Water turbidity
Quartz foul
Start-up / out-specification operation / shut-down
Feb 2009
125
Chapter 9
QNet in micro-infection investigation & problem solving
Feb 2009
126
Setting up a QNet
Only setting up a QNet when reoccurrence of micro-infection is high and daily
solution does not give sustainable improvement
Steps to build up QNet and investigation of micro-infection
Identifying process flow and machine boundary (the closed product source of supply)
related to the detection point of product micro-infection normally P&I is used
Identifying all product inflows, outflows to external extents of the machine boundary P&I
and/or site check
Identifying all product internal flows in machine boundary P&I and site check
Identifying, marking all machine components in the boundary and defining their functions
Defining possible soil sources of soil and soil characteristics on each machine component
Defining possible sources of micro-infection, if necessary extra detection point is installed,

at each machine component
Hygiene and CILT audit on site to check for compliance at least 3 times at different
moment. The more auditing times, the more problem is found because of more
opportunities to catch abnormally
Restoring basic conditions according to Hygiene requirements
Feb 2009
127
Setting up a QNet (cont)

Steps to build up QNet and investigation of micro-infection (cont)
Defining reverse clockwise activities of a full cycle (repeat activity) and flow routes of each
product flow machine component.
Check generation points (of soil, infection according to above identification), detection point
and control points of all cycles. Make correction or improvement
Check if the micro-infection is eliminated
If not, repeat the same steps to the upstream (inflow) process flow/machine boundary and
downstream (outflow) process flow / machine boundary
Defining also the reverse clockwise activities of new process flows/machines, sources of
soil/contamination, generation point, detection point and control point. Make correction or
improvement
Update new control point and condition in QM for training, monitoring
Feb 2009
128
Internal flow
Function:
CIP to
spray ball
Detection point
Product
inflow
Function:
Product
supply
Product
inflow
Function:
CIP supply
Feb 2009
Product buffer tank system
Product outflow
Function:
product
discharge
Product outflow
Function: overflow
from filling
129
Product
inflow
Function:
Water supply
CIP system
Water
Product
inflow
Function:
CIP supply
Feb 2009
New
detection point
Caustic
Product outflow
Function: CIP
supply to Buffer
tank
Product outflow
Function: overflow
from filling
130
Feb 2009
131
Weekly cleaning
Pre-rinsing
Buffer tank - process flow cycle
Caustic medium change
Level making-up
New
generation point
Supplying fresh water at

30% tank level to 80%
Waiting
Caustic rinsing
Supplying water till

level drops to 30%
Post rinsing water

Product buffering
Level making-up
Flushing in tank, pipe
Fresh water tank process flow cycle
Filling and supplying

Emptying
Sterilization
New
detection point
Pre-rinsing
Sterilizing
Cooling (fresh water)
Waiting (time)
Product buffering
Flushing in tank
Filling and supplying
Detection point
Emptying
Weekly cleaning
Feb 2009
132
Feb 2009
133
Feb 2009
134
END
Feb 2009
135

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VBL Microbiology Workshop

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Microbiological defect and off-flavor

Phenolic, Smoke, DMS

Sweat, Cheese, Iso-valeric acid

Milky, Vingar, Propionic acid

Rotten apple, H2S

Buttery, Cheese, Rancid

Le Quang Hai - VBL Technological Controller

Wort, Fermentation, Beer

Micro-organisms (ex: flourescence method)

Le Quang Hai - VBL Technological Controller

Reclamation of beer spoilage in Germany

Le Quang Hai - VBL Technological Controller

Use O2 as a food electron acceptor in

Required O2 < 0.2 atm

Not require O2 to growth but utilize it when

Exclusively anaerobic (fermentative) type

Le Quang Hai - VBL Technological Controller

Micro-organism type (cont)

With acid degree or pH value

With water and other nutrient (sugar, minerals)

Le Quang Hai - VBL Technological Controller

Efficiency CIP (cleaning and disinfection)

Le Quang Hai - VBL Technological Controller

Biofouling and Biofilm

Le Quang Hai - VBL Technological Controller

What are bio-fouling and biofilm

Bio-fouling: undesired deposit and growth of microorganisms on

Le Quang Hai - VBL Technological Controller

Examples of biofouling, biofilm

Le Quang Hai - VBL Technological Controller

Examples of biofouling, biofilm (cont)

Le Quang Hai - VBL Technological Controller

Examples of biofouling, biofilm (cont)

Le Quang Hai - VBL Technological Controller

Affection of biofoul & biofilm

Health: release of pathogens in water

Le Quang Hai - VBL Technological Controller

EPS: house of the cells

Le Quang Hai - VBL Technological Controller

Step formation of biofilm

Le Quang Hai - VBL Technological Controller

EPS and micro-organisms infection

Le Quang Hai - VBL Technological Controller

Examples of biofouling, biofilm

Le Quang Hai - VBL Technological Controller

Examples of biofouling, biofilm

Le Quang Hai - VBL Technological Controller

Where are biofilms in water system

Le Quang Hai - VBL Technological Controller

Mushroom model of biofilm

Le Quang Hai - VBL Technological Controller

Mushroom model of biofilm (cont)

Le Quang Hai - VBL Technological Controller

Principles to reduce biofoul & biofilm

Tolerance of biofoul/biofilm growth: applying risk management in terms

Cleaning: is more important than killing biofilm organisms. Setting up a

Le Quang Hai - VBL Technological Controller

Biofilm growth and threshold

Le Quang Hai - VBL Technological Controller

Reynolds index for pipeline: Re = rv/n