Module 06 Packaging Introduction

IGB GENERAL CERTIFICATE IN 1
Programme
BREWING & PACKAGING
Module 6 ‘Packaging’
Total time 120 minutes

Lecture - 80 mins.
• Tutorial 1 Dilution and losses calculations - 20 mins
• Tutorial 2 Comparison of benefits of sterile
filtration v tunnel pasteurisation – 20 mins.
• Discussion – Questions
• Homework.
INSTITUTE & GUILD OF BREWING GENERAL CERTIFICATE IN BREWING & PACKAGING 2001
2
Institute and Guild of Brewing

General certificate in brewing
& packaging
Bright Beer, Pasteurisation
Sterile Filtration
The General Aims of Packaging
3
Programme
Candidates will be expected to describe, simply but
accurately, the key features of bright beer handling and
the principles underpinning the operation of a single type
of beer packaging operation.
Key procedures for the transfer of filtered beer into bright
beer tank.
The importance of maintaining a constant beer temperature
before and after filtration.
Storage time.
Need to exclude air/oxygen
Beer pasteurisation and sterile filtration.
Calculation of blending ratios for the dilution of beer brewed at
high gravity.
4
Filtration to Bright Beer Tank
• Filter at as low a
temperature as possible
• -1 to -2oC BRIGHT
• Use trim chiller BEER
TANK
• Must ensure that no chill
haze already captured in
the filter is redissolved
• Ensure no ingress of
oxygen
FILTER
Bright Beer Tanks 5
– Must be clean and sterile

– Control temperature TOP PRESSURE
– lagged pipework
– lagged or cooled vessels
INERT ATMOSPHERE BRIGHT
– Control gas content
BEER
– Inert gas top pressure LAGGED/COOLED TANK
– Carefully controlled TANK
– Ensure no fobbing, take care with
degassing LAGGED PIPEWORK
– Smooth bends and correct transfer

speed
– Any fobbing reduces later beer foam SMOOTH
potential FILTER TRIM CHILLER PIPE
BENDS
6
Bright Beer Tanks

• Keep to maximum time in tank
• 2 - 3 days
• Buffer between packaging and filtration
• Risk of haze and micro infection
• Warm beer cannot be packaged
effectively
• Must recheck haze and dissolved gases
every shift
7
Bright Beer Tanks
• Blending
• Beer presented for packaging
must be in specification for all
analysed parameters
• Any blending at bright beer stage
must ensure that the mix is
consistent over the entire batch. + =
• Need as complex plant as beer
dilution with no pressure surging
or ingress of air
• Probably better to blend ex
maturation tank
Beer pasteurisation and 8
sterile filtration
• and sterile
Achievement filtration
of microbiological
stability
• Residual organisms can cause
haze and off flavours
• Tunnel pasteurisers. Obesumbacteria
• Flash pasteurisers.
Lactobacillus
• Sterile filtration.
Pediococcus
Acetobacter
9
Beer pasteurisation
– Killing bacteria using heat.
– Need to limit the amount of heat because beer
flavour is affected.
– Pasteurisation units
– 1 pasteurisation unit represents the lethal effect of holding beer
at 60oC for 1 minute
– Higher temperatures give more PUs per minute
61oC - 1.4PU, 62oC - 1.9PU…70oC - 28PU
– A total of 10 to 25 PUs over the entire heating and cooling cycle
are sufficient to pasteurise without flavour damage
– For some organisms lower temperatures means less lethal and
more will survive
– Pasteurisation is not sterilisation, for some organisms
10
Pasteurisation units
100
10
1
60 67 74
Temperature for 1 minute
Flash Pasteurisers
11
– High temperature short time using plate heat exchangers. Around

75oC for 20 seconds
– Use where tunnel pasteurisation is not practicable
– Cold incoming beer is warmed in the regeneration section by beer
that has just been pasteurised.
A hot water heating section raises it to the temperature of
pasteurisation
Held in holding tubes for a precise time which ensures the correct
PU input
– Important to control pressure to maintain gas content
– Rapidly cooled to filling temperature
– Must not recirculate for long periods to avoid flavour change
– Check by studying charts of time and temperature
12
Flash Pasteuriser
Slides by courtesy of Bass Brewers
13
Schematic of a flash pasteuriser

Heating Cooling
o
71 C Section Section 7oC
Regen.
Section
Beer out
3oC
95% regeneration
( 75 - 3 ) x 0.05 = 3.6oC
Beer in
75oC Holding tube
3oC
Types of pasteuriser 14
• Tunnel pasteuriser
– Operate from 61 to 63oC
– Often double deck
– Water sprays heat up and cool down the bottles or cans
– Control allows rapid cooling of sections adding too many PUs
especially if hold ups downstream
– Will delay throughput as pasteuriser gets back up to
temperature
– Checked by a thermograph or “ Redpost ”
Pre-heat zone Pasteurisation zone Cooling zone
Bottles 61-63oC Bottles

in out
3-4oC 25-30oC
15
An alternative to heating
• Membrane filtration
– Filter medium has carefully sized holes,
0.45 will trap bacteria and yeast Microbes
trapped in
the filter
Beer flow
– Will blind quickly on heavy loading, need
a standby filter
Microbes
– Beer is not heated so oxygen and haze
formation reactions are not accelerated
for flavour and shelf life should
improve
16
The General Aims of Packaging
• To provide the customers with a choice of

package.
• To protect the beer’s quality.
• To assist in marketing the product.
• To ensure that legal requirements are met.
• To control costs.
• To protect staff and customer’s health and
safety.
17
Packaging Aims
• Types of package
• Bottle
– Returnable or non returnable
– glass or PET
– Colour of glass
– Size and labelling
• Cans
– Size and graphics
• Kegs and casks
– Pasteurised?
– Sediment, reseeded or bright?
– Font and clip design
• Cellar tanks
18
Packaging Aims
• Quality
• Beer
• Beer temperature during filling.
• Counter pressure.
• Gentle filling.
• Reduce air pickup.
• Hygiene standards.
• Stabilisation.
• Package standards.
• Quality monitoring. Quality.
19
Packaging Aims
• Marketing.
• Logo and Company image
• Themes and families
• Promotion
Bloggs'
Beers
2
Current packaging designs 0
21
6 pack sleeve
15 pack suitcase
8 pack sleeve
12 pack suitcase 24 pack printed film and tray
4 x 275 2
2
5 litre minikeg
1.5 litre bottle 4 x 275
2
Packaging Aims 3
• Legal requirements.
– Volume of beer.
– Measurement of alcohol content ABV.
– Inspection systems
– Records
• Traceability and to demonstrate compliance.
– Shelf life
• Best before date depends on market
• Home sale, cask 4 weeks, keg 6 weeks, bottles 9 months
• Export 12 to 18 months
• There must be no deterioration of flavour or clarity before that date
2
Packaging Aims 4
• Cost control.
• Plant efficiencies
• Crewing hours, shift patterns and meal breaks
• Monitor breakdowns and improve maintenance
• Loss reduction
• Beer and materials
• Detergent use
• Energy conservation
• wastage of water at filler and pasteuriser
2
5
Packaging Aims
• Health & Safety
• Glass
• Noise
• Slips trips and falls
• Machinery
• Detergents
• Manual handling
• Gases
• Fork lift trucks
• .
2
6
Calculations on losses and

dilution
2
7
Dilution calculation
• You have 1000hl of beer in CT60 at
7.2%ABV
• How much water should be added to
produce beer in BBT at 4.5%?
2
8
Dilution calculation
• You have 1000hl of beer in CT60 at 7.2%ABV
• How much water should be added to produce
beer in BBT at 4.5%?
• Work in hectolitre % alcohol units
• CT60 contains 1000 x 7.2 = 7200hl%
• At 4.5% the volume would be 7200/ 4.5 =
1600hl
• Therefore should add 600hl
2
9
Dilution calculation 2
• You have 500hl in CT61 at 7.0%ABV and 1000hl in
CT62 at 7.4%ABV
• You have to produce 1600hl at 4.5% in BBT. You
must empty CT61. How much beer is needed from
CT62?
3
0
• You have 500hl in CT61 at 7.0%ABV and 1000hl in CT62
at 7.4%ABV
• You have to produce 1600hl at 4.5% in BBT. You must
empty CT61. How much beer is needed from CT62?
• CT61 will yield 500 x 7.0/4.5 = 777.7hl
• Leaving 822.2hl to be filtered and diluted from CT62
• That is 822.2 x 4.5 = 3700hl%
• Which is derived from 3700 / 7.4 = 500hl from CT62
31
Alternative approach
• You have 500hl in CT61 at 7.0%ABV and 1000hl in CT62

at 7.4%ABV
• You have to produce 1600hl at 4.5% in BBT. You must
empty CT61. How much beer is needed from CT62?
• You need to make 1600 x 4.5 hl% = 7200hl%
• In CT61 there are 500 x 7.0 = 3500hl%
• So you need 7200 - 3500 = 3700hl% from CT62
• CT62 is at 7.4% so volume needed is 3700 / 7.4 = 500hl
3
Dilution calculation 3 2
• You have to blend 800hl at 6.6%ABV in CT64 and

600hl at 6.3%ABV in CT65 to produce beer at
4.1%ABV
• How much diluted beer would be produced and
what volume of diluting water is needed?
3
Dilution calculation 3 3
• You have to blend 800hl at 6.6%ABV in CT64 and

600hl at 6.3%ABV in CT65 to produce beer at
4.1%ABV
• How much diluted beer would be produced and
what volume of diluting water is needed?
• CT64 would yield 800 x 6.6 / 4.1 = 1287.8hl
• CT65 would yield 600 x 6.3 / 4.1 = 921.9hl
• Total diluted beer = 2209.7hl
• Beer volume in CT was 1400hl so 809.7 hl of water
were added
3
4
Process loss calculations

• What have you got now?
• What did you start with
• Loss% is the difference divided by the
starting quantity x 100
• CT60 contained 1000hl at 7.2%ABV
• It was filtered and diluted to BBT1 at
4.5%ABV which contained 1590hl
• What is the loss?
3
5
Process loss calculations

• CT60 contained 1000hl at 7.2%ABV
• It was filtered and diluted to BBT1 at 4.5%ABV
which contained 1590hl
• What is the percentage loss?
• What have you got now? 1590 x 4.5 = 7155hl%
• What did you start with? 1000 x 7.2 = 7200hl%
• Loss is 7200 - 7155 = 45hl%
• Loss percentage = 45/7200 = 0.625%
3
6
Process loss calculations 2

• You pump 1000hl from FV20 at 7.0% and
add 50hl of recovered beer at 5.0% from
SBT1.
• You produce 1040hl at 6.9% in CT66
• What is the % process loss?
• Ignore the generation of centrifuge
discharge
3
Process loss calculations 2

7
• You pump 1000hl from FV20 at 7.0% and add 50hl of

recovered beer at 5.0% from SBT1.
• You produce 1040hl at 6.9% in CT66
• What is the % process loss?
• What have I got? 1040 x 6.9 = 7176hl%
• What did I start with? 1000 x 7.0 = 7000hl% from
FV20 plus 50 x 5.0 = 250hl% recovered beer
• Total input = 7250hl%
• Loss is 74hl%
• Loss % = 74/7250 x 100 = 1.02%
3
Tutorial on Process Losses

8
• Volume filtered from maturation

vessel was 1000 hl at 6.5%
• Volume diluted into bright beer tank
was 1235 hl at 5.2%
Calculate the beer loss.
3
Tutorial on Process Losses

9
• Volume filtered from maturation vessel was

1000 hl at 6.5%
• Volume diluted into bright beer tank was
1235 hl at 5.2%
• Got? 1235 x 5.2 = 6422hl%
• Start with? 1000 x 6.5 = 6500hl%
• Loss? 6500 - 6422 = 78hl%
• Loss% = 78 x 100/ 6500 = 1.2%
Tutorial 2 Compare Sterile
filtration with 4
0
pasteurisation
Property Tunnel Pasteuriser Sterile Filter
Capital Cost
Space
Reliability
Ease of Monitoring
Maintenance
Revenue Items
Laboratory attention
Beer Quality
Control
Operator involvement
Chance of error

Chose best option for each property – e.g Sterile filter requires less Space
41
Questions. Bright Beer

• What is an ideal bright beer storage temperature ?
……………………………………………………………………
• What is the maximum residence time in a bright
beer tank ?
……………………………………………………………………
• What information must be included on a bottle
label ?
……………………………………………………………………
• What are the benefits of tunnel over plate
pasteurisation ?
4
Questions. Packaging Aims 2
• Why package beer ?

……………………………………………………………………
• What is the most significant factor in beer
ageing after packaging ?
……………………………………………………………………
• What quality checks are made on packaged
beer?
……………………………………………………………………
• What do container inspectors inspect before
filling ?
Home work –
Based in YOUR brewery Each 4
3
candidate should:
Look at Bright Beer.
• What is the maximum time in BBT.
• What temperature is the beer stored at.
• What is the temperature of beer at the filler.
• What gas is used to top pressure tanks.
Packaging Aims?
• How much of the business is in bottle, can keg and
cask.
• How much is returnable versus new glass.
• How many foreign ( non Brewery ) bottles come back.
• What are the legal requirements on alcohol, fill levels
in the package you are looking at ?

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IGB GENERAL CERTIFICATE IN 1

Total time 120 minutes

Institute and Guild of Brewing

– Must be clean and sterile

– Smooth bends and correct transfer

Bright Beer Tanks

– High temperature short time using plate heat exchangers. Around

Slides by courtesy of Bass Brewers

Schematic of a flash pasteuriser

Bottles 61-63oC Bottles

• To provide the customers with a choice of

12 pack suitcase 24 pack printed film and tray

1.5 litre bottle 4 x 275

Calculations on losses and

• You have 500hl in CT61 at 7.0%ABV and 1000hl in CT62

• You have to blend 800hl at 6.6%ABV in CT64 and

• You have to blend 800hl at 6.6%ABV in CT64 and

Process loss calculations

Process loss calculations

Process loss calculations 2

Process loss calculations 2

• You pump 1000hl from FV20 at 7.0% and add 50hl of

Tutorial on Process Losses

• Volume filtered from maturation

Tutorial on Process Losses

• Volume filtered from maturation vessel was

Questions. Bright Beer

Questions. Packaging Aims 2

• Why package beer ?

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