Microbiology in a Brewery

- A Small Overview

Dr. Dirk Bendiak

Molson Breweries

MBAC One Day Technical Meeting

January 2008
 Overview
Present the big picture of the subject.
Present an appreciation for the
problems that microorganisms can
cause.
 Agenda
Type of Microorganisms
Elimination of Microorganisms
Microbiological Control Program
 Types of microorganisms
Yeast
One organism desired - ale or lager
brewing yeast for specific brewing flavors.
 Yeast helpful hints
Supply ultra freezer or liquid Nitrogen
Concern for RD respiratory deficient
Propagation - aerobic growth
Pitching consistent
Yeast storage 2 to 4C use asap
Acid washing pH 2.2 to 2.4 for 2 hours
Generations purity concerns, 5 10
 Types of microorganisms
Wild Yeast
These types may influence brewing flavors.
(pof - phenolic off flavors in beer)
 Types of microorganisms
Bacteria
There are many types mostly Pediococcus and
Lactobacillus are major beer contaminants

Molds
Concerns with humidity in cellar areas added
growth.
In packaging areas can impart musty flavors.
 Types of Microorganisms
Growth rate of Microorganisms
Aerobic or facultative - bacteria, wild
yeast and molds require oxygen
Fast growing, visible colonies in 3 days
20 to 40 min doubling times
Consequence Wort DMS
Indication of sanitation conditions
 Types of Microorganisms
Anaerobic - bacteria (Lactobacillus and
Pediococcus) and few wild yeast
Slow growing, visible colonies in 7 days
some even longer and slower at tiny in 10-
14 days
Potential beer spoilers - growth through
fermentation and storage affecting
flavor of product
 Sources
Malt - 107 organisms/
gram of grain.
Hops - 103 organisms/
gram hops.
Water - 100 organisms /100 ml
variation of 4C in winter to 20C in summer
Think about the kg malt kg hops hl water.

Wort is boiled and sterilized.

Biofilms in the brewery create the problems.

Sources - 6 inch water line
 Elimination of Microorganisms

Ultraviolet Light
Mechanical
Chemical
Heat
Elimination of Microorganisms

Ultraviolet light:
* Destroys cell membrane and/or nucleus
(DNA)
* Dependent on contact time and light
intensity
* Needs to be maintained and clean to work
properly
Elimination of Microorganisms

Mechanical:
Scrubbing with chemicals
Destroys cell membrane and/or nucleus
(DNA) - removes biofilms
Filtration
Porous Stainless sterile, Membranes,
Reverse Osmosis, HEPA
Elimination of Microorganisms

Chemical
Chlorine - sanitizer
Caustic - cleaner
Alcohol -
Iodine
Peroxides
Quaternary Ammonium
Peracetic acid
Elimination of Microorganisms

Heat
Effective if cleaning is done first
Steam
Hot water - 80oC for a minimum of 20
minutes
 Microbiological Stability
Refrigeration
Chemical Additives SO2
Pasteurization
Cold Filtration and Aseptic Filling
 Microbiological Control Program

Invasion Control
Proliferation Control
Daily Management
Detection and Identification
Hazard Warning
Information Management
Education
 Microbiological Control Program

Invasion Control:
Design of facilities that make it difficult for
microorganisms to invade
* Sterile filling rooms
* Mix Proof Valves
* Well designed piping, No hoses.
 Microbiological Control Program

Proliferation Control
Complete cleaning, sterilization and
elimination of microorganisms
* CIP system with verification monitoring
* ATP validation swabbing and final rinse water
* Sterilization system
* Hand scrubbing pumps
* Foam cleaning fillers and area
 Microbiological Control Program

Daily Management
* Monitor equipment - swabs/plating
* Monitor raw materials beer at all stages
of the process, air, CO2, water, etc.
* Monitor packaging materials - cans,
bottles, crowns, lids, fob water, rinse water.
 Microbiological Control Program

Detection and Identification

Sampling and specific plating and
incubation.
* Beer Spoilers
* Sanitation concerns - growth control.
 Microbiological Control Program

Hazard Warning:
* All microorganisms are potentially harmful,
all can grow and produce off flavors.
* Identification will warn of potential for beer
spoilers
 Microbiological Control Program

Information management
* To obtain the most up to date information
(plating results).
* To use these for making decisions.
* To use these to respond to problems.
 Microbiological Control Program

Packaging Information
Pasteurization - sampling is done to
measure general sanitation of the beer
delivery system and the filler
Draft - sampling done to measure
sanitation of beer delivery system, the
filler and potential for beer spoilage as
there may or may not be pasteurization.
 Microbiological Control Program

Education and Awareness

* Good equipment, good cleaning and
sterilizing systems are not a guarantee.
* Everyone must understand the importance
of sanitation.
* Must follow work standards (no shortcuts).
* Must be given the time to complete the
work as part of the process. (Fermenter fill,
ferment, collect CO2, empty beer, collect
yeast, clean, redo)
 Common System Failures

Engineering design important for CIP

Check valves eventually fail
Water lines in a brewery and cleaning ?
CIP systems must be audited each
cycle with CIP signoff by operators and
supervisors. Did it run and clean
properly?
 Conclusions
EVERY DAY BRINGS OPPORTUNITY
TO CAUSE A PRODUCT FAILURE.
Must strive to maintain the current level
of success. Can not sit on past success.
Routine monitoring and act on changes.
Must know, understand and follow
established procedures. Look for better
ways not short cuts.
Audit process for variations.
 Thank You

Any questions?