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Basic beer style parameters – Quality Control by basic means
Axel G. Kristiansen Deputy Director DTU Diplom
Danish Technical University
EBC Symposium 18 – 20 SEP 2016, Wroclaw
This presentation serves to put Quality as a disciplin on the agenda for small breweries as the Quality function is some times perceived:
• Requiring special staff
• Time consuming
• Costly
Claim 1: Quality Control can be implemented rather cheaply.
Claim 2: But missing quality however can be costly !
2 20-09-2016
The Quality Hierarchy of documentation
Useful Terminology for any brewmaster
Sample Plan List os samples taken during process: The sampling plan is maybe the most important element of the Quality System !
Recipe List of all ingredients incl. amounts. Does not explain the manufacturing process.
Process Description
Manufacturing guide to produce a defined amount of product on a defined plant.
Analysis A laboratory’s measurements of contents of certain contents in the product or in raw materials. Does not explain the used recipe or process.
Specification The brewery’s limits for which analytical values, we will accept for selected parameters.
Production log The brewery’s registrering of the used process for each batch, i.e. temperatures, times and volumes.
Declaration The Brewery’s garanti to the consumers and the authorities about certain contents in the final product. Does not explain the used recipe nor process. 5 20-09-2016
Content of Sampling Plan
• Sample ID – normally a number
• Sample type – e.g. ’boiled wort’
• Sampling point – e.g. ’wort kettle’
• Sample amount
• Frequency – e.g. ’daily’
• Responsible for sampling – e.g. ’Production’ or ’Laboratory’
• Sampling method – e.g. microbiological sample
• Analysis – verbal description, e.g. ’iodine test’
• Analytical method – e.g. EBC Analytica
• Responsible for the analysis – e.g. ’Production’ or ’Laboratory’
• Logging and reporting of results – reference to QM-system
• Recipients – the direct responsible for action/approval as well as copied
6
Example of Chemical Sampling Plan
7
Process Area
PRODUCT TYPE SAMPLE TYPE
SAMPLE FREQUENCY
ANALYSIS METHOD
SAMPLE SIZE
Fermentation Beer. Fermenting
Extract Chemical Daily Saccharometer 750 ml
Beer. Fermenting
VDK or Diacetyl
Chemical Each CCT, end of fermentation
EBC 9.24.1 500 ml
Beer. Fermenting
OE Alcohol pH Colour Bitterness
Chemical Each CCT, start of cooling
EBC 9.4 EBC 9.2.1 EBC 9.35 EBC 9.6 EBC 9.8
500 ml
BBT Filtered beer OE (+RDF) alcohol pH Colour CO2
Dissolved oxygen Haze Taste
Chemical, sensory
Each BBT
EBC 9.4 + 9.5 EBC 9.2.1 EBC 9.35 EBC 9.6 EBC 9.28.2 EBC 9.37 EBC 9.29
500 ml
Example of Microbiological Sampling Plan
8
Process Area
PRODUCT TYPE SAMPLE TYPE
SAMPLE FREQUENCY
ANALYSIS METHOD SAMPLE SIZE
Packaging, glass bottles
Beer before filler
Total counts (CFU)
Beer spoilage
organisms
Micro-biological
Dynamic DEV Nähragar
NBB bouillon
Min. 8 l container
Packaged beer flash pasteurised only Shelf life
Total counts (CFU)
Beer spoilage
organisms
Micro-biological
At start and each change Daily Weekly Check
DEV Nähragar
NBB bouillon
Visual control of sample after
storage
2 contain. 1 contain. 1 contain.
Washed bottles for aseptic filling
Total counts (CFU)
Beer spoilage
organisms
Micro-biological
Weekly Dynamic
DEV Nähragar
NBB bouillon
8 contain.
CIP Last rinse water
Total counts (CFU)
or Beer spoilage
organisms
Micro-biological
Weekly Dynamic
DEV Nähr agar
100 ml
9 20-09-2016
Example of the simplest production log: Brewhouse log
Example of a production log: Idealised fermentation chart
10 20-09-2016
Fermentation control: Temperature and % Plato during fermentation:
Allows the Brewer to spot slow fermentations and when fermentation
has ended. Cost and effort: Almost nothing.
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Days fermented
% P
More completed Fermentation Chart: Included some actions and some QC data
11
Beer Brew
No.
CB 5-9
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 28 29 30
23-Jun 24-Jun 25-Jun 26-Jun 27-Jun 28-Jun 29-Jun 30-Jun 01-Jul 02-Jul 03-Jul 04-Jul 05-Jul 06-Jul 07-Jul 08-Jul 09-Jul 10-Jul 11-Jul 12-Jul 13-Jul 14-Jul 15-Jul 16-Jul 17-Jul 18-Jul 19-Jul 20-Jul 21-Jul 22-Jul
14.0 14.0 14.0 14.0 14.0 14.0 14.0 14.0 14.0 14.0 8.0 2.0 0.0 -1.5
14.50 12.00 9.00 6.50 4.00 3.00 2.40 2.30 2.20
5.10 4.70 4.50 4.30 4.20 4.20 4.25 4.25 4.30 4.30
y c/d* c/d* d
13.0 21.0 43.0 29.0 15.0 8.0
142 96 59 36
Comments:
Carlsberg Operation Manual
Tank
Fermentation/Maturation Record
Yeast CroppingPitching controlYeast PitchingTank Vol.
hl (A)
2720
Aeration
DO ppm
11.0
type
25.0
rate, 106/ml (E)No.
5 252
gen
4
cells, 106/ml (B)
1430 13.0
vol, hl (G)
55
growth (H)
2.401560
cells, 106/ml (F)
pitched vol,
hl (J)
d* = draining day choosen depending on yeast sedimentation behaviour (i.e. at 4°C usually typical).
Must be continued periodically until Tank is emptied.
Day
Date
Temperature, 0C
% Plato
Operation
Yeast Count,
106/ml
Diacetyl, ppb
pH
% viabil. (C)
99
target pitching vol,
hl (D)
25.0
-- = 0C
-- = %P
-- = pH
-- = cells
-2.0
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
18.0
20.0
22.0
24.0
26.0
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
18.0
20.0
22.0
24.0
26.0
28.0
30.0
32.0
34.0
36.0
38.0
40.0
42.0
44.0
46.0
48.0
50.0
52.0
54.0
56.0
Day Zero is calculated from
"Pitched volume".
Yeast Count = (J x B x C) /
(A x 100)
Start cooling
when Diacetyl is
below 50ppb
In case of 2 Tank
fermentation: Transfer
through plate heat
exchanger to treatment
tank
What to measure ?
• Chemical parameters (Alcohol, Colour, Bitterness)
• Microbiology (level of infection, pitching yeast standard)
• Raw material checks (malt, hops, glass bottles)
• Flavour (positive flavors and off – flavors)
• Packaging quality (fill level, labelling standards)
• Customer satisfaction (product shelf life)
• Manufacturing logs:
• Raw materials used
• Mashing diagrams
• Fermentation logs
• Samples taken / analysed
12 20-09-2016
Example of Wort chemical Analysis - basic
13 20-09-2016
Only 7 chemical parameters define our Basic Beer Style and - Quality
1) Original Extract OG [% P] g/100 g
2) Color EBC Units
3) Haze 20 oC EBC Units
4) Real Degree of Fermentation RDF [%]
5) pH [number]
6) Alcohol by Volume ABV [%] ml/100 ml
7) CO2 [%] g/100 ml
20-09-2016 15
These 7 chemical parameters can all be measured in the brewery by simple means
16 20-09-2016
The brewer’s choices
1. Basic instruments: Cheap
2. Basic instruments: Costs < 2000 €
3. Portable instruments: Costs > 2000 €
17 20-09-2016
Crushed Malt after the mill – often forgotten
18 20-09-2016
Visual examination of crushed malt enables checks for:
• whole kernels (should not be there !)
•That all kernels are squeezed
• Some flour – not too much
19
Brewhouse test: Iodine test Shows, whether the mash has converted
19 20-09-2016
Extract analysis in spent grains: Shows whether we obtain the extract from the malt
20 20-09-2016
Example of a spent grains press Saccharometer
Refractometer: Shows OG of wort
21 20-09-2016
Refractometer,
hand held
Microbrewer using refractometer
Accuracy: +/- 0.2 % P
Obs.: Other limitations;
but convenient
Refractometer,
Lab. Bench type
Saccharometer Shows OG of wort
22 20-09-2016
Saccharometer Selection of Saccharometers Reading af
Saccharometer
Accuracy: +/- 0.1 % P
Use of Saccharometer in practice as seen still in many breweries
23 20-09-2016
Time consuming – very manual
Pycnometer
Methods with highest accuracy:
Densitometry using Pycnometry
24 20-09-2016
Accuracy: +/- 0.03 % P
Shows OG of wort
pH – meter Used for control of mashing – and wort boiling pH control
25 20-09-2016
Lab bench pH - meter Students measuring wort pH
Accuracy: +/- 0.1 pH
More Brewhouse tests
Break formation measured
by an Imhoff cone
26 20-09-2016
For check of efficiency of wort boil: For check of fermentation start:
Wort aeration checked by
a simple flow meter
...and some packaging tests, simple, yet useful some are rarely seen used…
27 20-09-2016
Humidity test - labels Glue test Air in headspace test
CO2–measurement of bottled beer to ensure same pressure in each bottle
20-09-2016 28
Fast – not so accurate
Taste testing: A Powerfull Quality – and Diagnostic
Tool to reveal process defects
29 20-09-2016
Taste test scores:
The brewers choices
1. Basic instruments: Cheap
2. Basic instruments: Costs < 2000 €
3. Portable instruments: Costs > 2000 €
30 20-09-2016
The microscope – cheap, yet powerfull
31 20-09-2016
Microscope found in the brewmaster’s
Office next to his PC.
Acetic Acic bacteria found
In draft beer from a brewery
Microscope
32 20-09-2016
‘’FermentoFlash’’ – example of a fast way of obtaining a chemical beer analysis
• Alcohol (% v/v & w/w)
• Extract – real & apparent
• Original gravity
• Density
• Osmotic pressure
• Degassing of sample
• 10 ml sample
• Analysed in 1 minute
• Printer or PC
• Calibration with reference beer (up to 18 different)
• Prize: ~ 2000 € + VAT
www.funke-gerber.de
33 20-09-2016
Accuracy: +/- 0.02 % ABV
The brewer’s choices
1. Basic instruments: Cheap
2. Basic instruments: Costs < 2000 €
3. Portable instruments: Costs > 2000 €
34 20-09-2016
Portable Density Meter to achieve fast and accurate chemical parameters
• Density
• Specific gravity
• Extract
• Alcohol
• Viscosity 0 – 1000 mPa*s
• Temperature compensated 0 – 40°C
Sample: 2 ml
Time: Few seconds
Price: Approx. 2000 €
www.anton-paar.com
35 20-09-2016
Portable CO2 / DO Measurement to measure Oxygen take – up during production
Anton Paar – CarboQC
www.anton-paar.com
Dr. Thiedig – Digox
www.thiedig.com
Pentair’s CO2 Gehaltemeter
www.Pentair.com
36 20-09-2016
Several suppliers
Lab. bench Methods – accurate, not cheap
High accuracy (do You need it ?)
Densitometry using automatic apparatuses
(most common is PAAR densitometer based on ultrasonic vibrations. The PAAR unit may be a stand-alone or may be built into an automatic complete wort analyzer called a SCAWA)
37 20-09-2016
Automised micro methods
Aber instruments: Lab Yeast
Analyzer:
Viability by. capasitans
metering
Chemometec: NucleoCounter
viabilitet by Iodine staining
Beckman Coulter: Vi-Cell
viabilitet by Trypan Blue
staining in flow cell
38 20-09-2016
Customer’s satisfaction – some times forgotten
39 20-09-2016
1. Do You know, what your customers think
of your beers in trade ?
2. Winning beer competitions is nice, but your
everyday customer pays your income
3. Do You systematically collect complaints
statistics and use complaints for process
Improvements ?
Axel G. Kristiansen
Thank you for your attention !
Conclusion:
Quality can be managed and product consistency achieved even on a small Budget and using limited efforts !
