INTRODUCTION TO

BREWING AT
FULLERS

1
 CONTENTS
BREWHOUSE 5 • END PROCESSING 27
• Brewing Liquor 6
• Beer Conditioning 28
• Raw Materials 7 • Cask Beer 30
• Milling 8
• Conditioning / Racking
• Mashing 9 • Tank 32
• Extract 12 • Filtration Aids 33
• Starch Degradation 13
• Filtration 34
• Wort separation 15 • Bright Beer Tank 36
• Hops 16
• Small Pack Quality
• Wort Boiling 18 Control 39
• Wort Clarification • Bottling 40
& Cooling 19 • Canning 42
• Wort Analysis
• Pasteurisation 44
Examples 20
• Kegging 47
• End Processing Food
FERMENTATION 21 Safety 48
• Carbohydrate
Metabolism 23
C. I .P 49
• Nitrogen
Metabolism 24 RECOMMENDED
• Fermentation READING 51
Profiles 25

2
 MALT
THE BREWING PROCESS
SILO

BREWING
LIQUOR

COPPER
MILL / WHIRL
MASH TUN POOL

FERMENTATION

PARAFLOW
SWEET WORT

CONDITIONING BRIGHT BEER

TANKS TANKS FLASH PASTEURISER

BOTTLES / CANS
OR
MATURATION KEGS
TANKS

RACKING
TANKS
CASKS
3
 The Brewing Process
• MILLING - malted barley is crushed to form a coarse
flour called grist
• MASHING - grist is added to liquor to form a porridge-like
mash. This activates the enzymes, thus enabling them to
solubilise the protein and starch fractions of the
endosperm
• WORT SEPARATION-the aqueous extract, called wort,
is separated from the spent solids using a mash tun
• WORT BOILING - the wort is boiled in the presence of
hops which impart bitterness and aroma. Boiling sterilises
the wort, coagulates some proteins and causes formation
of colour compounds. The spent hop material along with
some protein, known as trub, is removed by whirlpool
action.
• FERMENTATION - the wort is then cooled to 17°C and
transported to the fermentation vessel. The wort is
aerated & pitched with yeast. Fermentation proceeds
until much of the carbohydrate is converted to alcohol
and carbon dioxide. Higher alcohols and other yeast
metabolites (for example esters) contribute to beer
flavour and aroma.
• END PROCESSING - beer is then conditioned to modify
the flavour and aroma before clarifying. All beer
characteristics are checked and adjusted to within
specification. The beer is packaged into cask or filtered
and pasteurising before being packaged into keg, bottle
or can.
4
BREWHOUSE

5
 Brewing Liquor
• Water Treatment - removal of hardness by heating & acid
addition
• Direct Flavour Effects - Na+ sweet (salty in excess) / Mg2+
bitter, sour / Fe3+ metallic / Cl- fullness / S04 2- astringency /
K+ salty
• Indirect flavour effects - yeast requirements / pH / enzymes
during mashing Keep calcium >150ppm. Four times more
calcium than malt oxalate required

pH CONTROL
• Bicarbonate more influential at raising pH than calcium at
lowering
• Carbonate : bicarbonate buffer system
Ca 2+
H20 + CO2 HCO3- CO3 2- CaCO3

• Calcium : malt buffering system

3 Ca 2+ + 2 HPO4 2- 2H+ + Ca3(PO4)2
Polypeptide --H + Ca 2+ Polypeptide--Ca + 2 H+
• High bicarbonate high wort pH due to removal of H+
• Calcium reacts with malt protein to reduce wort pH /
increased run-off rate / increased extract recovery / increased
TSN & FAN / precipitation of oxalate

6
 Raw Materials
Pale Ale Malt
• Malted barley
• Concentrated source of starch
• Starch consists of unbranched helical amylose [200-
400 D-glucose units linked via α−1,4-positions] AND
branched amylopectin [D-glucose units linked via α-
1,6 and α -1,4 links. Up to 6000 glucose units]
molecules.
• Barley starch granules : large granules supply most of
the brewers extract (20 - 25µ) and small starch
granules (1 - 5µ)
• Barley protein : 30% glutelin (dissolves in weak
alkali)+ 37% hordein (dissolves in 80% alcohol)+ 11%
albumin (dissolves in water)
• High molecular weight proteins : improve head
retention
• Low molecular weight proteins : amino acids and small
peptones for fermentation are haze precursors
• Fats : husk and aleurone layer e.g. stearic acid, oleic
acid, linoleic acids = long chain fatty acids. Detrimental
to beer foam, but required for membrane synthesis.

7
 Raw Materials

Coloured Malts & Adjuncts

• Crystal Malt - contributes colour (150° EBC colour
units)and malty / nutty / toffee / fruity notes to
London Pride, Chiswick Bitter & ESB
• Chocolate Malt - contributes colour & flavour to
London Porter
• Amber Malt - contirbutes colour (45°EBC colour
units) and sweetness and dryness to 1845
• Malted Wheat - contributes fullness and fruity notes
to Summer Ale along with more protein for head
formation

8
 Milling
Mechanical breakdown of dry goods to produce grist.

Preparation of grist for the mash tun

Keep husk material in-tact to act as filter bed during
wort recovery
• Endosperm material into small particles, grits,
which readily hydrate during mashing to reactivate
the malt enzymes giving us maximum extract.
• Dry milling - 4 roller mills with 2 pairs of contra-
rotating rollers.
• Proportions of coarse grits (0.3mm-0.6mm
diameter):fine grits (0.15mm - 0.3mm): flour
(<0.15mm) ratios vary from 27:35:38 to 24:35:41
• Gypsum (calcium sulphate) is added to the grist as
it is produced (see liquor treatment page)
• Grist transferred via conveyor to grist hoppers
above mash tuns

9
 Mashing
Hydrate grist and activate enzymes to form
soluble substances for fermentation

• Hot liquor (69°-71°C) comes into contact with

the grist in the ‘Steels Masher’ to achieve a
mash temperature of 65°C in the mash tun
• A porridge-like mash is formed with a bed
depth of 1.5-2.0m in the mash tun
• The mash tun has a false / slotted floor 5mm
from the base of the vessel and the mash sits
on this for 55mins. The false floor is flooded
with hot liquor before mashing starts to
remove the air
• During this period starch is degraded by
amyloytic enzymes forming sugars (primarily
maltose) and protein is further degraded by
proteases. The cell wall material is also further
degraded by glucanases
• Important flavour developments occur during
mashing as a result of the starch degradation

10
 Mashing Enzymes

ENZYME ACTION OPT. OPT.

pH TEMP
Protease Hydrolysis of proteins - 52°C
to amino acids
Beta - Breaks gummy beta- - 60°C
Glucanase glucans into shorter
chains
Beta – Attacks reducing end 5.4 62°C
Amylase of starch to give
maltose

Alpha – Random hydrolysis of 5.7 67°C

Amylase starch to form
dextrins

11
 Extract -L°/Kg and %
w/w
• EXTRACT - amount of substances in solution
from raw materials under controlled conditions
(IOB L°/Kg or EBC %w/w)
• %w/w sucrose = °Plato or °Brix (approximately
SG ÷ 4)
• Determining extract (malts) small scale mash
50g in 515 ml solution & measure °excess
gravity
L°/Kg = 10.13 x °excess gravity
°excess gravity = L° / 10.13
%w/w sucrose = 0.2601 x L° - 0.364
L°/Kg = 3.845 x % w/w sucrose + 1.178

12
 Starch Degradation
• Gelatinisation - starch granules swell with water
and finally burst viscous/sticky solution which can
be directly attacked by enzymes.
• Liquefication - rapid reduction of viscosity by α-
amylase attacking gelatinised amylose and
amylopectin
• Saccharification - α-amylase continues random
attacks and β-amylase attacks new non-reducing
ends to form maltose
IODINE TEST
• Blue = gelatinised starch / large dextrin's
• Violet / Red = Medium size dextrins
• Iodine normal = small dextrins / maltotriose /
maltose / glucose

13
 Wort Separation
The sugar solution, wort, is separated from the grains

• Filtration process with the husk as the filter bed

• Recirculation - bed settling and wort clarification
• 1st stage - first wort or strong wort collection (high in
extract)
• 2nd stage - sparging the spent grain with liquor to
remove extract
• Last runnings - 1004° (0.5°P). Leave polyphenolic &
tannin material from husks
• Spent grains - 70% water[28% protein; 8.2% fat;
41% N-free extract; 17.5% cellulose; 5.3% inorganic
material].
• Extract recovery 98-100%
• Turn around time 3 hours.

14
Hops - Humulus lupulus
The Hop Plant
• Perennial, dioecious climbing plant belonging to
the Cannabis family; only female plant bears hop
cones
• Grown in temperate climates eg. UK, NZ, North
USA
• Hop cone (or flower) contains 14 - 21% hop resin
which houses the α-acids (humulone; cohumulone;
adhumulone) which are needed by the brewer
• Hop cone contains 0.5-1.5% essential hop oils
which give beer its characteristic hoppy aroma
• Hop pellets are concentrated from hop cones and
used at Fullers
• Different hop varieties offer different characteristics
to the beer eg. floral, spicy, woody, citrus notes
• Some varieties used at Fullers include Target,
Northdown, Challenger, Goldings all grown in the
UK

15
 Hops

Hop Chemistry
• The α-acids are isomerised (chemically changed)
during wort boiling to give iso-α-acids (isohumulone;
isocohumulone; isoadhumulone)

Use Of Hops
• Kettle hopping - added at the start of the boil to
covert the non-bitter α-acids to bitter iso-α-acids
• Late Hopping - aroma hops added late to boil /
remaining oils give late hop characters
• Dry hopping - addition of hop cones directly to the
cask during racking

16
 Wort Boiling
• Traditionally a copper vessel used
• Now we have two 520 HL stainless steel coppers
where the wort is boiled
• The wort is continuously pumped from the vessel to
an external calandria (called the EWB=external wort
boiler) for heating & returned to the vessel
tangenitially (at 90°)

Chemisty
• Formation of bitter compounds
• Wort sterilisation
• Precipitation of calcium phosphate & proteins
causing the pH to drop from 5.4 to pH 5.2
• Evaporation and hence concentrate the wort
• Inactivation of enzymes
• Formation of flavour active compounds
• Formation of colour compounds
• Protein & tannin coagulation which is removed as
trub from the base of the vessel after the whirlpool
sequence
• Removal of undesirable volatiles
17
 Whirlpool
This is a method of separating the hot boiled wort from
the trub

• After the boil is complete the wort iwe continue to

pump the wort from the base of the vessel and
return at relatively high speeds tangentially (<5m/s)
into the vessel, this creates a ‘spinning’ action in the
vessel.
• The wort pumping is stopped, and the wort is
allowed to spin freely for 20 minute.
• As it loosses momentum the heavier ‘trub’ material
settles in the trough at the base of the copper
• Trub material is composed of hop materail which
protein, polyphenol & tannins have become adhered
• When the wort is run-off for cooling and pumping to
fermentaion vessel it is drawn through a pipe above
the trough so the trub is left as a waste material
• Longer stands allow more SMM (sulphur methyl
methionine) from malt to be converted to DMS
(dimethyl sulphide) a strong flavour compound (50-
60ug taste threshold) % DMSO (dimethyl
sulphoside). Most DMS formed and lost due to its
volatility during wort boiling.

18
 Wort Cooling
Quick cooling of the wort via a paraflow

• This cooling removes the cold break (small

particles (<0.5um) of protein/ polyphenol / hop) and
prepares the wort ready for yeast addition.
• The paraflow is a heat exchanger made up of 100
plates with chilled liquor (<10°C) on one side and
hot wort on the other.
• This large surface area allows the heat from the
wort to heat up the liquor (thus cooling the wort
itself) which returns to the liquor tanks for the next
day brewing.
• The wort is cooled to 17°C ‘en route’ to the
fermentation vessel

19
FERMENTATION

20
 Fermentation
Conversion of wort sugars to form alcohol & other
flavour components

100 g Maltose + 0.5 g Amino acid 5 g Yeast +48.8 g

Ethanol +46.8 g CO2 + 50kCal Energy

• Wort is made up of 70% Maltose; Maltotriose 18%;

Sucrose 5%; Glucose 5%; Fructose 2%
• Pitching (adding) viable yeast at 10 million cells per ml is
added to the wort from the paraflow to the fermentation
vessel
• Air is added in-line or directly into fermentation vessel at
the start of fermentation this is so the yeast can for
materials needed for new cell membranes & walls
• The air is switched off and anaerobic metabolism by the
yeast of the wort sugars continues to form alcohol &
carbon dioxide
• Initial lag phase then exponential growth until alcohol &
lack of energy source limits growth
• pH decreases from pH 5.0-4.9 during fermentation due to
formation of organic acids / uptake of ammonium ions
NH4-/ release of H+ ions
• Diminishing food supply & increasing ethanol - yeast
cannot tolerate so growth subsides after 3-4 days
21
 Carbohydrate
Metabolism
• Sequence of sugar uptake :(a) glucose, fructose, sucrose
(b) maltose (c) maltotriose
• Anaerobic respiration via the glycolytic or Embden -
Meyerhof Parnas pathway
• A small proportion of acetyl Coenzyme A is formed
during the fermentation from pyruvate via the TCA cycle.
TCA cycle also yields oxo acids & NAD. Acetyl Co A is
important in production of fats & esters and amino acid
synthesis.
• Without oxygen, fatty acids & sterols can not be
synthesised to form membranes & yeast can not tolerate
the ethanol concentration so growth ceases.
• Acetyl CoA + alcohol ester + Co A
e.g. Acetyl CoA + ethanol ethyl acetate + Co A
Palmityl CoA + glycerol glycerol tripalitate (a fat) +
Co A
• Higher alcohol production from carbohydrate metabolism
(via pyruvic or oxaglutaric acid) or nitrogen metabolism

22
 Nitrogen Metabolism
• Amino acids in wort used for protein synthesis / DNA &
other cellular structures
• Arginine; aspartic acid; asparagine; glutamic acid;
glutamine, lysine; serine; threonine can be used only at
start of fermentation. Other amino acids are made by the
yeast cell. During this production the equivalent amount of
oxo acid is made by the glycoltic pathway to accept NH2.
• Nitrogen deficiency but oxo acid production continues.
Reduced to alcohol.
• Production Of Flavour Compounds
• Amino acid deamination (removal of amino NH2 group)
and decarboxylation (removal of CO2) higher alcohols are
formed
e.g. leucine pentanol + ammonia + CO2
• intermediate products are aldehydes which are also
flavour active
e.g. valine oxovalerate isobutyraldehyde
isobutanol
• Acetolactate is decarboxylated then chemically oxidised to
form diacetyl (undesirable butter flavour). Yeast is capable
of reducing diacetyl to 2,3- butanediol which is flavourless
at concentrations found in beer. At the end of fermentation
a warm conditioning period takes place to allow the yeast
to carry out the reduction process.

23
 G R A V IT Y °P L A T O

0
2
4
6
8
10
12

0
2
4
6
DAYS
FERMENTATION PROFILES

pH

8
GRAVITY

YEAST COUNT

10
12
0
10
20
30
40
50
60
70

Y E A S T C E L L C O U N T S m illio n c e lls p e r m l
 Fermentation
SUGARS AMINO ACIDS SULPHATE

SO2 & H2S

PYRUVATE KETO ACIDS

PENTANE
DIONE
ACETOLACTATE ACETALDEHYDE
ACETYL CoA
ETOH
DIACETYL ISO BUTANOL

FATTY ACYL CoA HIGHER

ALCOHOLS
FATTY ACIDS
ESTERS

LIPIDS
 MALTOSE MALTOTRIOSE
maltase

SUCROSE GLUCOSE
hexokinase, glucokinase
invertase
GLUCOSE-6-
invertase
PHOSPHATE
glucose-phosphate isomerase
FRUCTOSE FRUCTOSE-6-
PHOSPHATE
phospho fructokinase

FRUCTOSE-1,6-
DIPHOSPHATE

PHOSPHOENOL
PYRUVATE
pyruvate kinase

Anaerobic PYRUVATE
Metabolism pyruvate decarboxylase

ACETALDEHYDE

alcohol dehydrogenase

ETHANOL

26
 Beer Maturation /
Conditioning
Natural refinement of beer flavours

• After fermentation all Fullers beers are centrifuged to

remove any excess yeast
• Beers for kegging, canning or bottling go to
CONDITIONING at 10°C
• Beers for cask go to MATURATION at 6°C
• En route to these individual departments a small
amount of yeast is re-introduced in to the beer stream
• A period (5-7 days) of warm conditioning or secondary
fermentation is allowed in which the yeast reduces
buttery flavours (due to the compound diacetyl) and
modifies green, grainy flavours to more rounded malty
notes along with production of carbon dioxide
• Beers from maturation are then ready for cask racking
• Beers in conditioning tanks are then cooled rapidly to
-1.5°C to ensure residual protein comes out of solution
and can be removed during filtraion

27
END PROCESSING

28
 End Processing

1. CONDITIONING TANK / RACKING TANK

2. FILTRATION AIDS CASK

3. FILTRATION

4. BBT

5. BOTTLING 6. CANNING 8.KEGGING

7. PASTEURISATION 7. PASTEURISATION 7. PASTEURISATION

29
 Cask Racking
Beer from maturation tanks is pumped to the racking
tank for filling into cask

• Fermentable extract remains in this beer (or honey

primimgs for HoneyDew is added) and yeast (0.25 - 2.0
million cells / ml)
• Run into racking tank (auxiliary finings for protein
removal is added)
• Casks filled directly or via racker under counterpressure
from a smaller tank, the Jack Back.
• Chiswick Bitter & ESB are dry hopped (a nugget of
compressed hop flowers is added to each container)
• Isinglass finings - collagen net which traps the
negatively charged yeast and brings it into the belly of
the cask after 24-28 hours is added as the cask is filled.
• Cellar - 13°C for secondary fermentation to proceed
which conditions’ the beer (3-5 days). CO2 escapes via
soft spile.
• Soft spile is replaced with a hard spile after conditioning
to keep air out.

30
 2. Filtration Aids

• Porous materials which are used on a solid

support to trap particles and prevent the
system from clogging which are made from: -
Keiselguhr fossils of primitive organisms
(diatomaceous earth) or perlite from volcanic
origin
• Polyvinylpolypyrrolidone (PVPP) - added at
filter or impregnated in filter sheets removes
polyphenolic material.
• Filter sheets:
– Coarse 2.5 - 5 µm
– Medium 2.5 - 3.5 µm
– Fine 1.2 - 1.8 µm
– Sterile 0.8 - 1.2µm

31
 3. Filtration
Aim : to clarify the beer by removing yeast cells, non-
biological haze particles and biological particles in
some cases
Basic Principles : unfiltered liquid enters the filter with
a higher pressure than the clear filtrate on the outlet
side which drives the process.
• Filter Mass - cellulose pads on a hollow frame
structure through which beer is forced
• Powder filtration - slurry of kiesulguhr pumped onto
filter mesh as precoat then beer + kieselguhr
pumped through under pressure & recycled until
clear. Then beer + ‘bodyfeed kieselguhr’ pumped
through filter
• Filter sheets - cellulose, cotton, kieselguhr or perlite
sheets on a hollow framework. Depth filtration &
Adsorption filtration
• Membrane filtration -filtrate passes via pores 0.01-
1µm on support membrane whilst beer is
recirculated.
Precautions : keep DO2 to a minimum by filling empty
spaces with high quality deaerated liquor; <5°C so
haze precursors in solution.
32
 Plate & Frame
Filtration
Unfiltered beer

Plate & Cloth Plate & Cloth

Kieselguhr

Frame
Frame

Filtrate

33
 4. B.B.T (Bright Beer
Tank)
QUALITY CONTROL
• Alcohol - blend or use deaerated liquor
• Colour - caramel & malt extracts
• pH
• Sensory perception
• Bitterness - blend or iso-/ tetra hop additions
• Flavourings - fruit essences for example
• Carbonation / Nitrogenation - direct injection /
hydrophobic membrane technology
• Propylene glycol alginate (PGA) - 30-50 g/Hl
protects beer foam from lipid damage &
enhances foam stability

34
 Small Pack Quality
Control
5. Bottling 6. Canning
BOTTLES (IOB methods 13.8 - CANS (IOB methods 13.2-13.7)
13.17)
• Visual inspection -
• Visual Inspection - incorrect pallet
physical damage, colour formation, physical
quality, bar code damage, missing cans,
legibility, defective / foreign cans, bar code,
excessive lacquer, print & decor quality,
overall damage on excessive / defective
receipt external lacquer)
• Physical Dimensions • Check internal lacquer
• Capacity Determination integrity (& external
• Light Transmission lacquer Contamination of
• Visual inspection of can ends
crown corks & coating
integrity
• Visual inspection of PET
& closure & oxygen
permeability

35
 5. Bottling - filling
• Bottle cleaning: presoak; 60 - 85°C hot caustic
baths; hot caustic rinse; hot water rinse; cold water
rinse & then demineralised water rinse. Inspection
(previous slide)
• Vacuum filling : 0.93 - 0.98 bar under pressure in
bottle so liquid is sucked in. Used for milk, wine,
juices.
• High vacuum filling : high viscosity beverages such
as liqueurs
• Pressure filling :the pressure is the same in the filler
and bottle
• High pressure filling : filler pressure higher so forces
liquid in
• Amount of beverage metered by mass, volume of fill
level
• Machines : rotate with up to 200 filling valves.
50,000 - 100,000 bottles / hr
• Filling sequence : bottle is pressed against the filling
element, evacuated and counterpressurised (x1 or
x2), filled, fill height corrected, pressure released,
bottles lowered and released.
• Capping machine : fine water jet so beer fobs
expelling air from bottles before capped by crown
36
cork.
 5. Bottling - labelling

• Body labels / back labels / chest labels / neck

labels and top & wrap around foils
• Require high quality paper, ink, graphic design
often metallization / lacquers / glazes are used
which must be resilient to wet or dry conditions
and tolerate caustic
• Adhesive - too thick then time to removal; too
thin not properly stuck. Can be starch, dextrin,
casein, vegetable based.

37
 6. Canning - filling
• Advantages : unbreakable, lighter, no return, stable,
easy opening, good space utilisation, advertising
space, impermeable to light, pasteurised in
container
• Body = steel or aluminium 0.25, 0.33, 0.44 or 0.5
litre
• Lid = aluminium 2.06 or newer 2.02 diameter and
0.27mm thick
• Best before date - laser application to base
• Can rinsing - depalletised & rinsed to remove dust
• Filling sequence : filling element lowered onto can &
forms air tight seal; pressed against can; evacuated
and counter pressurised with CO2; beer flows from
14/16 small tubes in filler valve due to differential
pressure between filling chamber and can; release
pressure and gentle discharge to avoid spilling.
• Can sealing : stage 1 - rest lid on can in carousel in
a predetermined place and press with a preroller so
bend outer part of lid under body lip. Stage 2 - press
with a seaming roller.

38
 7. Pasteurisation
AIM: prolong shelf life of beer/cider by inactivating all
micro-organisms which could cause chemical changes
to product
•Shelf-life also prolonged by low pH; ethanol; CO2 &
certain hop compounds
•Lethal effect on organisms from 53°C
•1 PU = the lethal effect produced by holding for one
minute at 60°C. Increases tenfold for every 7°C rise in
temp.
PU = t x 10 -(60-T)/Z

t = holding time T = heating

temperature in °C
Z = increase in temp for a tenfold reduction in death
rated (or D factor = reduction in number of organisms
from 100% to 10% under these conditions)
Egs. Lager 20 PU; low alcohol 40 PU; no-alcohol 80 PU
PRECAUTIONS : damage to sensory perception by
over pasteurisation and DO2 levels > 0.3ppm.

39
 7a. FLASH PASTEURISER FLOW
DIAGRAM
Hot
Water
Set
Steam
Inlet

1
IN

SBT
Glyc
ol

TO DRAIN

40
 7b. TUNNEL PASTEURISER
DIAGRAM

C
a
n
s
ConveyorZONES :Reg. heating Superheat Holding temp Reg.
Cooling Cooling
26° C 37° C 46°C 66°C 62°C 44°C 35°C 24°C

Heat transfer into bottles / cans - convection heat

transfer from the sprays; conduction through the wall of
bottle / can & free convection from
container to product. Heat transfer coefficient calculation
:
1/U = 1/αext +δ/λ + 1/α int
αext = external heat transfer coefficient; δ = thickness of
container wall;
λ = thermal conductivity of container material; α int =
internal heat transfer coefficient.
Cold spot - middle of container, near base is the last
place to heat
Temperature & rate of conveyor control number of PU’s
41
 8. Kegging
• Advantages : metal closed containers; easy to
handle; fully automatic cleaning & filling; returnable
• Spear or extractor is attached to a keg valve fitting
which allows cleaning, filling & emptying without air
ingress.
• Dispense head ( well type (sanky) or flat top
(grundy) or combi fitting) with beer supply pipe
attached locks onto spear and contents can be
extracted
• Keg cleaning sequence : depalletising and
separation; inversion so keg valve fitting at bottom;
decapping; pressure testing; external cleaning;
loading onto racker ; pressure release; residue
expulsion; water rinse; water blow out; caustic wash;
blow out; hot water wash; blow out with steam;
steaming; venting; CO2 pressure; release head and
discharge.
• Keg filling sequence : loading; pressure application;
testing; head rinsing; blow out; coupling; venting;
counterpressurising (CO2 or N 2); begin fill; rapid fill;
throttling; end fill; head blow out & rinse; release;
discharge and cap

42
Packaging Food Safety
Aspects
GLASS - crown cork liner Azodicarbonamide
needs to be fully converted during heating
otherwise ethyl carbamate which is
carcinogenic is formed (2mg/l in fresh beer
from yeast metabolism).
METALS -metal pick up is minimal due to
lacquers but keg lacquers can be damaged by
CIP spray jets over time. Damaged kegs / cans
can leach metals in contents.
• aluminium no legal limit but low limit in water
• Steel / tinplate - possible iron leaching / legal
limit for tin is 200mg/Kg
• Lacquers - BADGE (bisphenol A diglycidyl
ether) is carcinogenic and Bisphenol A mimics
oestrogen but is v. insoluble in beer.
PET / PEN -phalates from the plasticide coatings

43
 Cleaning -In-Place
ENERGY
• Sprayball - low pressure, high volume & lower cost
• Direct Jet Heads - high pressure, low volume & higher
costs
• Mains water - Reynolds No >2000
CHEMICAL STRENGTH
• Acid 0.5 - 5%
• Caustic 0.5 - 5% e.g.... sodium hydroxide 3% in
brewhouse
• Disinfectant / Sanitizer 0.25 - 1%
TEMPERATURE
• Casks / Kegs / Bottles 80°C
• Brewhouse / FV 65 - 80°C then hot & cold rinse

44
 Brewing Detergents
PROCESS DEPOSIT DETERGENT

Brewhouse proteins, tannins caustic / chlorine

Fermentation proteins, tannins, yeast, caustic / acid

calcium

Storage tanks proteins, calcium caustic, chlorine, acid

Casks / Kegs calcium, yeast acid / caustic

45
 Recommended
Reading
• Technology Brewing & Malting Int. Ed 2. - Kunze VLB
Berlin
• Brewing Science & Technology Series II Volume 1,2,3 & 4.
IOB publication
• Beer - Tap into the art and science of brewing -
C.W.Bamforth
• Malting & Brewing Science - Hough, Briggs & Stevens
(1971)
• Development in packaging of alcoholic drinks - Peter Bathe
(PIRA International)
• Beer Pasteurisation - EBC manual of Good practice 1995
• Cask Conditioned Beer - Manual of Good Practice 1985
(BRI publication)
• Theory & Practice of beer clarification by R.V. Leather- The
Brewer October 1994
• Basic Mechanisms of Brewery Solid-Liquid Separations by
M. McKechnie; G. Freeman - Brewers Guaradian Aug &
Dec 1996

46