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GCP (All Containers): Section 1: An overview of beer & beer packaging

Institute of Brewing and Distilling

General Certificate in Beer Packaging
Section 1
An Overview of Beer and Beer
Packaging.
1.1. Definition of Beer and Beer Types
In its basic sense, beer is an alcoholic beverage produced by the fermentation
of sugars derived from malted barley and flavoured with hops.
There are some minor differences where malt is supplemented with adjuncts
or where the hops are replaced by other flavours, but this definition would be
recognised by the majority of people round the world.
The manufacture of all alcoholic beverages utilises the ability of yeast to
ferment sugar into alcohol.

SUGAR YEAST ALCOHOL

Wine is made from grapes, cider from apples, whereas in the case of beer,
the sugar is derived from malted barley and flavour and character comes from
the addition of hops. The full process also involves preparing the immature or
green beer for consumption.

MALTED HOPS
BARLEY

BEER
SUGAR YEAST 'GREEN
FOR
BEER'
SALE

CARBON
DIOXIDE

Different types of beer.

Different areas around the world have developed their own types of beer.
The variations have come about through a combination of the materials
available for its manufacture and the tastes of the consumers.

Lager is by far the biggest proportion of beer sold. Its delicate flavour comes
from:-

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 1: An overview of beer & beer packaging

• The use of a malt that is relatively undermodified and lightly kilned.

• A relatively low bitterness.
• The use of a bottom fermenting yeast.
• Cold maturation.

Ales are produced mainly in the United Kingdom and the Republic of Ireland.
Their flavours come from:-
• The use of a well modified and biscuity flavoured malt which is sometimes
highly coloured.
• Sometimes they are very bitter.
• The use of a top fermenting yeast.

Ales come in various forms, bitters, pale ales and mild beers.

Wheat beers are lagers produced from the use of malted wheat instead of
malted barley.

Stouts are very dark in colour and richly flavoured from the use of highly
coloured malts or roasted barley.

Low alcohol / alcohol-free beers are produced by several different processes

and their definition varies in different countries.
Usually alcohol-free means less than 0.05% (vol/vol) alcohol and low alcohol
means less than 0.5% (vol/vol) alcohol (less than 1.2% in UK).
• Often produced by removing alcohol from standard strength beers (for
example, by evaporation or reverse osmosis methods).
• Can be produced by a very limited fermentation process, by making a very
low fermentable wort.
• Not to be confused with malt drinks, which are essentially unfermented
wort.

Low-carbohydrate beers are brewed by producing wort that is more

fermentable than in “standard beers” by several techniques, but usually by
adding additional enzymes to convert more of the non-fermentable sugars into
fermentable sugars. These enzymes may be produced from unboiled wort
and added to conventional wort, or from commercial suppliers derived from
fungal and/or bacterial sources and added during wort production or during
fermentation. The overall objective by making the wort more fermentable than
standard (or “super-attenuated) is to brew products that have lower
carbohydrate content in the finished beer.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 1: An overview of beer & beer packaging

1.2. The Definition of Beer Packaging and General Aims

The general aims of packaging beer are to:-
• Provide the consumers with beer in a convenient package of their choice.
• Ensure that the quality of the beer is protected during packaging
operations.
• Ensure that the quality of the beer is protected during its shelf life.
• Assist in the marketing of the product by presenting the package in an
attractive form.
• Ensure that the requirements of the relevant authorities (for example,
Excise) are met.
• Control the costs of packaging to an economic minimum.
• Protect the health and safety of the people who work in the packaging
areas and the consumers.

Many of these aims are required so that “due diligence” with regard to safety
of product, consumer and operator is ensured.

The procedures used to ensure that these aims are met are detailed in the
tables below:-

How to provide the consumers with a convenient package of their

choice.

Package type. Procedure.

Returnable bottle. • Choice of different sizes.
• Choice of different shapes.
• Choice of different glass colour.
Non-returnable bottle. • Choice of different sizes.
• Choice of different shapes.
• Choice of different glass colour.
• Choice of different glass weight.
• Choice of different pack/box etc.
Can. • Choice of different sizes.
• Choice of different ‘end’ opening.
Keg. • Choice of different sizes.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 1: An overview of beer & beer packaging

How to ensure that the quality of the beer is protected during packaging.

Package type. Procedure.

Returnable • Bottle at low temperature to keep dissolved gases in solution.
bottle. • Reduce air pickup during bottling to a minimum.
• Fill against a counter pressure to prevent fobbing and loss of
dissolved gases.
• Monitor beer quality from bright beer tank to final package.
• Ensure that hygiene standards for bottle washing and bottling plant
are maintained.
• To protect beer from contamination by pasteurization or sterile
filtration.
Non-returnable • Bottle at low temperature to keep dissolved gases in solution.
bottle. • Reduce air pickup during bottling to a minimum.
• Fill against a counter pressure to prevent fobbing and loss of
dissolved gases.
• Monitor beer quality from bright beer tank to final package.
• Ensure that hygiene standards for bottling plant are maintained.
• To protect beer from contamination by pasteurization or sterile
filtration.
Can. • Can at low temperature to keep dissolved gases in solution.
• Reduce air pickup during canning to a minimum.
• Fill against a counter pressure to prevent fobbing and loss of
dissolved gases.
• Monitor beer quality from bright beer tank to final package.
• Ensure that hygiene standards for canning plant are maintained.
• To protect beer from contamination by pasteurization or sterile
filtration.
Keg. • Fill kegs at low temperature to keep dissolved gases in solution.
• Reduce air pickup during kegging to a minimum.
• Fill against a counter pressure to prevent fobbing and loss of
dissolved gases.
• Monitor beer quality from bright beer tank to final package.
• Ensure that hygiene standards for keg washing and keg filling plant
are maintained.
• To protect beer from contamination by pasteurization or sterile
filtration.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 1: An overview of beer & beer packaging

How to ensure that the quality of the beer is protected during its shelf
life.

Package Procedure.
type.
Return- • Reduce air pickup during bottling to a minimum.
able bottle. • Small pack beer is usually stabilised.
• Pasteurisation or sterile filtration for microbiological stability. Over pasteurisation
reduces shelf life.
• Selection of the right type of glass. White or green bottles allow U.V. light to
adversely affect beer flavour. Full bottles should be kept in the dark.
• Ensure that hygiene standards for bottle washing and bottling plant are maintained.
Non- • Reduce air pickup during bottling to a minimum.
returnable • Small pack beer is usually stabilised.
bottle. • Pasteurisation or sterile filtration for microbiological stability. Over pasteurisation
reduces shelf life.
• Selection of the right type of glass. White or green bottles allow U.V. light to
adversely affect beer flavour. Full bottles should be kept in the dark.
• Ensure that hygiene standards for bottling plant are maintained.
Can. • Reduce air pickup during canning to a minimum.
• Small pack beer is usually stabilised.
• Pasteurisation or sterile filtration for microbiological stability. Over pasteurisation
reduces shelf life.
• Ensure that hygiene standards for canning plant are maintained.
Keg. • Reduce air pickup during kegging to a minimum.
• Pasteurisation or sterile filtration for microbiological stability. Over pasteurisation
reduces shelf life.
• Ensure that hygiene standards for keg washing and keg filling plant are
maintained.

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GCP (All Containers): Section 1: An overview of beer & beer packaging

How to assist in the marketing of the product by presenting the package

in an attractive form.

Package Procedure.
type.
Returnable • Maintain high standards of labelling.
bottle. • Ensure that bottle washing (exterior) is effective.
• Ensure that scuffed bottles are not re-used.
• Ensure that case washing is effective.
Non- ret. • Maintain high standards of labelling.
bottle. • Ensure that the multipacking and shrink film operations are run effectively.
• Ensure that secondary packaging operations are run effectively.
Can. • Ensure that the multipacking and shrink film operations are run effectively.
• Ensure that secondary packaging operations are run effectively.
Keg • Ensure that the external keg washing operation is run effectively.
• Ensure that containers are undamaged.

How to ensure that Statutory Taxation (Excise) requirements are met.

Package Procedure.
type.
Returnable • Ensure that bottles are not over filled.
and non • Ensure that the label states the correct contents and alcohol level.
returnable • Ensure that alcohol levels are analysed in package and that the relevant
bottle. records are kept.
• Ensure that full package level inspection is effective and that the relevant
records are kept.
Can. • Ensure that cans are not over filled.
• Ensure that the can states the correct contents and alcohol level.
• Ensure that alcohol levels are analysed in package and that the relevant
records are kept.
• Ensure that full package level inspection is effective and that the relevant
records are kept.
Keg. • Ensure that kegs are not over filled.
• Ensure that alcohol levels are analysed in package and that the relevant
records are kept.
• Ensure that full package contents inspection is effective and that the relevant
records are kept.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 1: An overview of beer & beer packaging

How to ensure that the requirements of “Trading Standards” are met.

Package Procedure.
type.
Returnable • Ensure that bottles are not under filled.
and non • Ensure that the label gives the correct information.
returnable • Ensure that full package inspection and analysis is effective and that the
bottle. relevant records are kept.
Can. • Ensure that cans are not under filled.
• Ensure that the can label gives the correct information.
• Ensure that full package inspection and analysis is effective and that the
relevant records are kept.
Keg. • Ensure that kegs are not under filled.
• Ensure that the keg label gives the correct information.
• Ensure that full package inspection and analysis is effective and that the
relevant records are kept.

Please note that national law and local regulations will vary in different countries and
that various authorities may differ in their interpretation of the law.

How to ensure that the Consumer Safety requirements are met.

Package Procedure.
type.
Returnable • Ensure that empty bottle inspection and the reject system is effective and that
bottle. the relevant records are kept.
Non- • Ensure that bottle washing/rinsing and plant hygiene procedures are effective.
returnable • Ensure that full package inspection and analysis are effective and that the
bottle. relevant records are kept.
• Maintain a system of handling customer complaints.
Can. • Ensure that empty can inspection and the reject system is effective and that
the relevant records are kept.
• Ensure that can rinsing and plant hygiene procedures are effective.
• Ensure that full package inspection and analysis are effective and that the
relevant records are kept.
• Maintain a system of handling customer complaints.
Keg. • Ensure that empty keg inspection and the reject system is effective and that
the relevant records are kept.
• Ensure that keg washing and plant hygiene procedures are effective.
• Ensure that full package inspection and analysis are effective and that the
relevant records are kept.
• Maintain a system of handling customer complaints.

Please note that national law and local regulations will vary in different countries and
that various authorities (such as Environmental Health Authority in U.K.) may differ in
their interpretation of the law.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 1: An overview of beer & beer packaging

How to protect the Health and Safety of the people who work in the
packaging areas.

Package Procedure.
type.
Returnable • Protect against broken glass.
and non • Protect against noise.
returnable • Protect against slips trips and falls.
bottle. • Protect against machinery accidents.
• Protect against detergent hazards.
• Protect against high carbon dioxide levels and against dilution of oxygen in air
by nitrogen.
Can. • Protect against noise.
• Protect against slips trips and falls.
• Protect against machinery accidents.
• Protect against high carbon dioxide levels and against dilution of oxygen in air
by nitrogen.
Keg • Protect against manual handling accidents.
• Protect against noise.
• Protect against slips trips and falls.
• Protect against machinery accidents.
• Protect against detergent hazards.

How to control the costs of packaging to an economic minimum.

Package Procedure.
type.
Returnable • Operate the plant effectively through effective maintenance, planning and staff
bottle. training to achieve the specified throughput.
• Reduce beer losses by controlling fill heights and filling machine operation.
• Control bottle washing detergent use.
• Control heat use during pasteurisation and optimise all heat recovery systems.
• Minimise electricity consumption by switching off equipment when not in use.
Non- • Operate the plant effectively through effective maintenance, planning and staff
returnable training to achieve the specified throughput.
bottle. • Reduce beer losses by controlling fill heights and filling machine operation.
Can. • Control heat use during pasteurisation and optimise all heat recovery systems.
• Minimise electricity consumption by switching off equipment when not in use.
Keg. • Operate the plant effectively through effective maintenance, planning and staff
training to achieve the specified throughput.
• Reduce beer losses by controlling fill heights and filling machine operation.
• Control keg washing detergent use.
• Control heat use during pasteurisation and optimise all heat recovery systems.
• Minimise electricity consumption by switching off equipment when not in use.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 1: An overview of beer & beer packaging

1.3. Packaging Types (Kegs, Bottles and Cans)

General.

The main aims of packaging beer are to provide the consumers with beer in a
convenient package of their choice and to ensure that the quality of the beer
is protected during and after packaging.

Consumer choice means that a range of beer packages are provided, for
example kegs, casks, bottles and cans.

The quality of the beer will have been established by the procedures adopted
in the production operations described above, packaging operations are
organised so that the quality is protected.

The two main ways of protecting quality during packaging are:

• Avoidance of contamination especially by air or micro-organisms.

• Microbiological stabilisation by pasteurisation or sterile filtration.

• Non-biological stabilisation by polish filtration.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 1: An overview of beer & beer packaging

Packaging into Kegs.

Keg
Empty
Wash &
Kegs Steam

Keg
CO 2
Pressure
Flash
Bright Pasteuriser
beer
tank
Keg Full
Fill Kegs

The packaging operation works as follows:-

• Empty kegs are transported, usually by conveyor to the fillers.

• They are check weighed to ensure they are empty.
• They are cleaned with detergent and rinsed via the single inlet/outlet
‘spear’.
• They are sterilised with steam.
• They are counter pressured with CO2 to exclude air and to control filling
rate.
• They are filled with pre-pasteurised beer.
• The full kegs are check weighed and transported to the warehouse.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 1: An overview of beer & beer packaging

Packaging into Bottles.

Empty Full
Bottles Bottles

Labeller
Bottle Washer

Bright Bottler &

beer Crowner
tank

Pasteuriser

The packaging operation works as follows:-

• Empty bottles are transported by conveyor from the de-palletiser and de-
crater to the bottle washer.
• In the washer, they are soaked in and jetted with detergent and then rinsed.
• They are inspected to ensure that they are empty and clean.
• They are transported to the filler where they are evacuated to remove any
air and then counterpressured with CO2 to exclude air and to control filling
rate. They are then filled to a controlled level.
• They are immediately closed with a crown cork.
• The full bottles are checked for contents level.
• They are pasteurised.
• They are labelled.
• Finally they are transported to the crater, palletiser and warehouse.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 1: An overview of beer & beer packaging

Packaging into Cans.

Tray packer
& Shrinkwrap

Empty Full Cans

Cans

Bright Canner &

beer Seamer
tank

Pasteuriser

The packaging operation works as follows:-

• Empty cans are transported by conveyor from the de-palletiser to the can
rinser. They are then inspected to ensure that they are empty and clean.
• They are transported to the can filler where they are flushed and then
counterpressured with CO2 to exclude air and to control filling rate. They
are then filled to a controlled level.
• They are then immediately closed with a can lid (end) in the seamer.
• They are inspected for contents level.
• They are pasteurised.
• Finally they are transported to the tray packing machine, shrinkwrap
machine, palletiser and warehouse.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)