BREWERY CHEMICAL PROGRAM and WATER CONSERVATION

Prepared By

Mike Willis

Certified Water Technologist

CHEMCO PRODUCTS COMPANY

State of California

State of California

What is a CHEMICAL PROGRAM?

• Cleaning & Sanitizing • Boilers, Cooling, Waste Water • Standard Operating Procedure (SOP)

Proper Program Saves:

• TIME • ENERGY • WATER

Where the Water Goes

Brewhouse44%

Washdown18%

Domestic/Irrigation13%

Keg Cleaner12%

Centrifuge6%

Bottler5%

Boilers2%

• Brewery gallons of water per barrel of beer. Information provided by Bear Republic Brewing

• Four Step Process

– Pre-Rinse

– Wash

– Post-rinse

– Sanitize

Cleaning and Sanitizing What is it?

Temperature

Concentration Flow

(Mechanical Action)

Time

Cleaning 4 Factors:

Soils in Brewery

• Protein

• Carbohydrates, Starches

• Minerals

• Oils

• Form Layers and Matrix (Kettle)

Protein Solubility

Mineral Scales

• Beer Stone

– Calcium Phosphate

– Calcium Carbonate

– Calcium Oxilate

• Water, Wort

• Remove with Acids

• New Additives for Caustic

– Can remove minerals

Caustic Additives

• New additives- cleans better at lower concentration, eliminate acid washes

– Saves water

– Saves time

– Saves heat

– Saves chemical

• Rinse better – saving water

• Penetrate soils

Wetting Penetration - Surfactants

Water Only: Beads Form

Water Plus Surfactant:

Soil Crack Soil

Rinsing

• Manual rinsing may be most effective in removing trub.

• Know how much water you need to rinse. (Validate time or volume for rinsing)

Burst Rinsing

Principals of CIP Engineering

Types of CIP Systems:

• Single Tank

• Re-Use

• Recovery

• Eductor Return

Single Tank CIP

2 Tank Re-Use CIP

3 Tank, Re-Use Rinse- Recovery CIP

Typical CIP VERIFICATION

1. Return Flow Verification

2. PRE-RINSE TO DRAIN 3. Return to Drain (repeat as necessary)

4. Establish Recirculation

5. Delay to Temperature

6. Delay to Concentration

7. WASH 8. Wash Recovery

9. POST RINSE 10. Return to Wash Tank/Reclaim Tank/Drain (repeat as necessary)

11. SANITIZE 12. Airblow to Drain

13. Return to Drain (tanks)

14. Drain System (lines)

• Conductivity Sensor

• Turbidity Sensor

• CIP validation-

Rinsing Sensors

CIP Time Savings with Additives and Validations

Sanitizing

• Use of high-acid sanitizers can eliminate acid wash or flush

– High-Acid PAA

– pH = 2-3

– PAA

– pH = 4-5

Chemical Concentrations FOLLOW THE SOP!

Boilers and Towers • Use boiler blowdown controller

• Return condensate

-1000

0

1000

2000

3000

4000

-1000

0

1000

2000

3000

4000

22 Sun 1 Tue 8 Tue 15 Tue

Waste Water

• Recycle

– Membrane Technology

• Boiler/Tower Makeup

• Washdown

• Bottle Cooler

Water Conservation

QUESTIONS