Best Practices for Quality Testing - QCL Sentinel Handbook copy v4.pdfA PROACTIVE APPROACH TO QUALITY AT YOUR BREWERY. TABLE OF CONTENTS ... Invisible Sentinel has been committed to

Best Practices for Quality TestingA P R O A C T I V E A P P R O A C H T O Q U A L I T Y A T Y O U R B R E W E R Y

T A B L E O F C O N T E N T SOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

Process Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 2 – 4

Ingredients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 5 – 7

Specialty Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 8 – 10

Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 11 – 13

The Value of Proact ive Test ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14

Test Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15

Post ive Experience from Key Brewers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 16

More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 17

OverviewDeveloped by brewers for brewers with sponsorship from Invisible SentinelThe brewing industry has grown exponentially over the past decade with new entrants crowding the market. Due to the variety of beer styles and brewing complexity, quality management has become a critical differentiator. The need for accurate and actionable information is essential to maintain quality and protect brand image.

This handbook has been developed in conjunction with leading breweries to assist brewers around the world in making better quality beer. By understanding the stages in the process and areas in the brewery that are susceptible to beer spoilers and implementing a microbial testing plan that makes sense for the specific needs of the brewery, costly issues can be eliminated and brand image can be protected. Developed by brewers for brewers, this handbook illustrates a comprehensive approach to quality microbial testing. The information can be used to tailor testing regimens to the needs of individual breweries.

For over a decade, Invisible Sentinel has been committed to providing game-changing technologies for microbial detection in the food and beverage industries. By partnering with leading breweries around the world and focusing on innovation, Invisible SentinelChas developed leading microbial detection tools specifically designed for beer producers.

Veriflow, Invisible Sentinel’s core technology platform, combines proven diagnostic principles for microbial detection with new, innovative, first-in-class scientific approaches. Veriflow is a robust, highly accurate, and user-friendly molecular detection system using DNA Signature Capturing Technology. The complete Veriflow-based portfolio of products, including the industry leading brewPAL assay, target a wide variety of beer spoilers and can be used at various stages in the process, to test ingredients, in finished products and for environmental testing. The test assays have been validated in a wide variety of matrices, even the most complex, and can therefore provide valuable information about the presence and persistence of organisms. These products offer simplicity, robustness and affordability and results in less than 4 hours.

P R O D U C T T A R G E T

For Hop-Resistant Pediococcus and Lactobacillus

For Latic Acid-Producing Microbes

For Brettanomyces/ Dekkera species

For Brettanomyces bruxellensis

For Megasphaera and Pectinatus

For Saccharomyces diastaticus

There is a portfolio of tests that can be used at the various testing points based on the beer spoiler assessment required and other variables that should be considered.

I N V I S I B L E S E N T I N E L | Advanced Beer Spoiler Testing 1

I N V I S I B L E S E N T I N E L | Advanced Beer Spoiler Testing

Process StagesHigh level view of where to testThis section focuses on the foundational stages of the brewing process and the illustration to the left shows the various stages that will be reviewed. As shown in the tables on the following pages, the highest priority for testing for stages in the process during fermenting, in the bright tanks, and during packaging. Even in a newly implemented quality testing program, proactive testing in these areas is essential.

MIL

LIN

G

MA

SH

ING

BO

ILIN

G

WH

IRL

PO

OL

ING

CO

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ING

F E R M E N T A T I O N

CO

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NIN

G/

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AR

IFIC

AT

ION

BR

IGH

T T

AN

KS

P A C K A G I N G

K E G B O T T L E S & C A N S L I B R A R Y S A M P L E S

2

A R E A T O T E S T =


Process StagesPrioritization of where to testThe table below highlights the areas in which a high priority should be placed on completing

proactive and reactive testing (Red). There are also several areas and spoilers that should be

tested as a brewer’s quality program advances. And lastly, there are several areas that should

be tested based on risk profiles.

S T A G E P R O A C T I V E T E S T I N G

R E A C T I V E T E S T I N G I N V I S I B L E S E N T I N E L T E S T K I T / S

Fermentation PAL, DEK, BRUX, LAP, STAT, MAP

Conditioning/clarification PAL, DEK, BRUX, LAP, STAT, MAP

Bright tanks PAL, DEK, LAP, STAT, MAP

Packaging: cans/bottles PAL, DEK, LAP

Packaging: kegs PAL, DEK, LAP

Library samples PAL, DEK, BRUX, LAP, STAT, MAP

P R I M A R Y T E S T I N G = S E C O N D A R Y T E S T I N G = T E S T B A S E D O N R I S K P R O F I L E =

T A B L E 1 . Overview for testing in STAGES IN THE PROCESS

3


Process StagesDetailed prioritization of where, how and when to testThe table below illustrates the importance of testing proactively and reactively for each area and for specific beer spoilers. In most of the key areas, testing for Pediococcus, Lactobacillus as and Brettanomyces bruxensis are critically important. There are also several areas that, based on various risk factors, can become critically important and should be aggressively assessed.

S T A G E P A L D E K B R U X S T A T L A P M A P

P R O A C T I V E P R E A C T I V E E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E

Fermentation

Conditioning/clarification

Bright tanks

Packaging: cans/bottles

Packaging: kegs

Library samples

P R I M A R Y T E S T I N G = S E C O N D A R Y T E S T I N G = T E S T B A S E D O N R I S K P R O F I L E = T A B L E 2 . Details for each assay type in STAGES IN THE PROCESS

4


IngredientsHigh level view of where to testThis section focuses on ingredients that are used in breweries and the illustration to the left overlays the wide variety of ingredients onto the diagram of the brewing process. As shown in the tables on the following pages, it is essential to test yeast, proactively and for several beer spoilers. Other ingredients such as wort in sour programs and all adjuncts such as flavoring should be considered for testing.

5

M I L L I N G+ Barley

WH

IRL

PO

OL

ING

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F E R M E N T A T I O N+ Yeast+ Blending Water+ Wort (Sour Program)

CO

ND

ITIO

NIN

G/

CL

AR

IFIC

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ION

PA

CK

AG

ING

M A S H I N G+ Water

B O I L I N G+ Wort+ Hops

B R I G H T T A N K S+ Adjuncts

BO

TT

LE

S&

CA

NS

LIB

RA

RY

SA

MP

LE

S

KE

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IngredientsPrioritization of where to testThe table below highlights the areas in which a high priority should be placed on completing proactive and reactive testing (Red). There are also several areas and spoilers that should be tested as a brewer’s quality program advances. And lastly, there are several areas that should be tested based on risk profiles.

I N G R E D I E N T S P R O A C T I V E T E S T I N G

R E A C T I V E T E S T I N G I N V I S I B L E S E N T I N E L T E S T K I T / S

Blending water PAL, DEK, BRUX, LAP, STAT, MAP

Wort in sour program PAL, DEK, BRUX, LAP, STAT

Yeast PAL, DEK, BRUX, LAP, STAT

Adjuncts DEK, BRUX, LAP, STAT


T A B L E 3 . Details for each assay type in INGREDIENTS

6

IngredientsDetailed prioritization of where, how and when to testThe table below illustrates the importance of testing proactively and reactively for each ingredient and for specific beer spoilers. There are also several areas that, based on various risk factors, can become critically important and should be aggressively assessed.

S T A G E P A L D E K B R U X S T A T L A P M A P

P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E

Fermentation

Conditioning/clarification

Bright tanks

Packaging: cans/bottles

Packaging: kegs

Library samples

P R I M A R Y T E S T I N G = S E C O N D A R Y T E S T I N G = T E S T B A S E D O N R I S K P R O F I L E = T A B L E 4 . Details for each assay type in INGREDIENTS

7 I N V I S I B L E S E N T I N E L | Advanced Beer Spoiler Testing


Specialty ProcessesHigh level view of where to test

8

This section focuses on specialty processes that are sometimes added to the overall brewing process based on the brewery’s approach to brewing as well as the variety of beers produced.

These processes by the nature of their complexity require an additional level of quality management and therefore it is important to conduct testing in most of these processes.

Ingredients such as wort in sour programs and all adjuncts such as flavoring should be considered for testing.

D R Y H O P P I N G

T A N K A D D I T I O N S

N O N - S O U R B A R R E L P R O G R A M

M I X E D F E R M E N T A T I O N S O U R P R O G R A M

P A S T E U R I Z A T I O N

F I L T R A T I O N / C E N T R I F U G A T I O N F O R C L A R I F I C A T I O N

F I L T R A T I O N F O R S T E R I L I Z A T I O N

B O T T L E C O N D I T I O N I N G

I N - L I N E C A R B O N A T I O N



Specialty ProcessesPrioritization of where to testThe table below highlights the areas in which a high priority should be placed on completing proactive and reactive testing (Red). There are also several areas and spoilers that should be tested as a brewer’s quality program advances. And lastly, there are several areas that should be tested based on risk profiles.

S P E C I A L T Y P R O C E S S E S P R O A C T I V E T E S T I N G

R E A C T I V E T E S T I N G

I N V I S I B L E S E N T I N E L T E S T K I T / S

Tank additions (for flavoring) PAL, DEK, BRUX, STAT

Non-sour barrel program PAL, DEK, BRUX, LAP, STAT

Sour barrel program PAL, DEK, BRUX

Mixed fermentation sour program PAL, DEK, BRUX, LAP, STAT

Pasteurization PAL, DEK, BRUX, LAP, STAT

Filtration/centrifugation for clarification PAL, DEK, BRUX, LAP, STAT

Filtration for sterilization PAL, DEK, BRUX, LAP, STAT

Bottle conditioning PAL, DEK, BRUX, LAP, STAT

In-line carbonation PAL, DEK, BRUX, LAP, STAT

P R I M A R Y T E S T I N G = S E C O N D A R Y T E S T I N G T E S T B A S E D O N R I S K P R O F I L E =

T A B L E 5 . Details for each assay type in SPECIALTY PROCESSES


Specialty ProcessDetailed prioritization of where, how and when to testThe table below illustrates the importance of testing proactively and reactively for each specialty process and for specific beer spoilers. There are also several areas that, based on various risk factors, can become critically important and should be aggressively assessed.

S P E C I A L T Y P R O C E S S E S P A L D E K B R U X S T A T L A P

P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E

Tank additions (for flavoring)

Non-sour barrel program

Sour barrel program

Mixed fermentation sour program

Pasteurization

Filtration/centrifugation for clarification

Filtration for sterilization

Bottle conditioning

In-line carbonation

P R I M A R Y T E S T I N G = S E C O N D A R Y T E S T I N G = T E S T B A S E D O N R I S K P R O F I L E =T A B L E 6 . Details for each assay type

in SPECIALTY PROCESSES



EnvironmentalHigh level view of where to test

11

This section focuses on environmental testing that should be considered and is often

essential for the production of quality beer. There are an almost unlimited number of

places in the brewery where beer spoilers can grow and cause significant issues. Even in

a newly implemented quality testing program, proactive environmental testing is essential.

Rinsates J E T T E R

T A N K S

P I P E S A N D H O S E S

P A R T S B I N S

B A R R E L S

C E N T R I F U G E , H E A T E X C H A N G E R

P A C K A G I N G L I N E( F I L L E R H E A D S , B O W L S , O T H E R )

Swabs T A N K V A L V E S

P A C K A G I N G L I N E ( F I L L E R H E A D S , B O W L S , O T H E R )

G E N E R A L B R E W E R Y S U R F A C E S

M I C R O L A B S



EnvironmentalPrioritization of where to testThe table below highlights the areas in which a high priority should be placed on completing

proactive and reactive testing (Red). There are also several areas and spoilers that should

be tested as a brewer’s quality program advances. And lastly, there are several areas that

should be tested based on risk profiles.


E N V I R O N M E N T A L P R O A C T I V E T E S T I N G R E A C T I V E T E S T I N G I N V I S I B L E S E N T I N E L T E S T K I T / S

R I N S A T E S

Jetter PAL, DEK, BRUX, LAP, STAT

Tanks PAL, DEK, BRUX

Pipes and Hoses PAL, DEK, BRUX, LAP, STAT

Parts Bins PAL, DEK, BRUX, LAP, STAT

Barrels PAL, DEK, BRUX, LAP, STAT

Centrifuge, Heat Exchanger PAL, DEK, BRUX, LAP, STAT

Packaging Line (filler heads, bowls, other) PAL, DEK, BRUX, LAP, STAT

S W A B S

Tank Valves PAL, DEK, STAT

Packaging Line (filler heads, bowls, other) PAL, DEK, MAP, STAT

General Brewery Surfaces PAL, DEK, STAT

Micro Labs PAL, DEK, STAT


T A B L E 7 . Details for each assay type in INGREDIENTS


EnvironmentalDetailed prioritization of where, how and when to testThe table below illustrates the importance of testing proactively and reactively for various environmental areas and for specific beer spoilers. There are also

several areas that, based on various risk factors, can become critically important and should be aggressively assessed.

E N V I R O N M E N T A L P A L D E K B R U X S T A T L A P M A P

R I N S A T E S P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E

Jetter

Tanks

Pipes and hoses

Parts bins

Barrels

Centrifuge, heat exchanger

Packaging line (filler heads, bowls, other)

S W A B S P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E P R O A C T I V E R E A C T I V E

Tank valves

Packaging line (filler heads, bowls, other)

General brewery surfaces

Micro labs

P R I M A R Y T E S T I N G = S E C O N D A R Y T E S T I N G = T E S T B A S E D O N R I S K P R O F I L E = T A B L E 8 . Details for each assay type in ENVIRONMENTAL



The Value of Proactive Testing

I M P A C T F I N A N C I A L I M P L I C A T I O N S

P R E S E N C EO F O R G A N I S M S

• Production delays• Finished product holds

• Labor inefficiencies• Reduced through-put• Revenue delays

P R O L I F E R A T I O NO F O R G A N I S M S

• Cross-contamination• Widespread impact

• Extra man-hours• Filtering, cleaning costs• Product loss

P E R S I S T E N C EO F O R G A N I S M S

• Scrapped packaging• In the hands of

customers

• Packaging expense• Recall costs• Damage to brand

Proactive testing with brew suite of detection tools...

Saves THOUSANDS in production inefficiencies and labor

Saves HUNDREDS OF THOUSANDS in potential recall or loss of product

SAVES UNMEASURABLE damage to brand reputation

Costs associated with proactive quality management for spoilage organism detection are more than offset by potential cost savings and loss prevention.

Whenever implementing new processes and additional technologies, it is important to understand the overall value of those new tools to the business. When a brewery puts in place proactive and reactive beer spoiler testing, with a technology that offers accurate, rapid and actionable results, there are several real economic benefits:

• Prevents processing, bottling, and shipping at risk

• Allows traceability to the point of contamination

• Reduces the risk of further contamination

• Protects against the recall of tainted beer

• Protects your brewery’s brand image

The presence, proliferation and persistence of beer spoilers can cause a wide variety of operational issues. These operational issues caused by beer spoilers that are undetected or detected late in the brewing process, or even after the beer is packaged, translate into real and sometimes substantial financial implications.

Use of Invisible Sentinel’s technology with its industry leading accuracy and sensitivity and the benefit of rapid, actionable results assist brewers in driving quality through the entire process and with any style beer. Implementing a quality testing program that is designed for the specific needs of the brewery, results in limiting the consequences and stop the cascade of undetected beer spoilers.

14


Test Protocol Detection is Simple and Fast

C O L L E C T I O N Collect sample and centrifuge. Resuspend sample using provided proprietary Buffer A.

A M P L I F YTransfer 5µ of resuspended sample into provided PCR reagent tube. Place tube into Thermocycler and run program.

A N A L Y Z ERemove PCR Tube from Thermocycler and add proprietary Buffer B. Dispense PCR Tube contents onto test cassette window. Wait 3 minutes and retract test cassette switch to reveal test results, two lines indicates semi-quantitative positive results.

15

I T E M # IS1020 IS1028 IS1022 IS1034 IS1042 IS1057 IS0904 ISTC002 ISRD001

D E S C R I P T I O NbrewPAL Complete Test System

brewDEK Complete Test System

brewBRUX Complete Test System

brewMAP Complete Test System

brewLAP Complete Test System

brewSTAT Complete Test System

Veriflow Loading Tray

Veriflow Thermocycler

Veriflow Reader

S I Z E1 Kit, 24 tests

1 Kit, 24 tests

1Kit, 24 tests

1 Kit, 24 tests

1 Kit, 24 tests

1 Kit, 24 tests 1 Unit 1 Unit 1 Unit

S T A R T - Minimal sample prep

2 . 5 H O U R A M P L I F I C A T I O N

C A S E T T E P R E - S A M P L E A D D I T I O N :Unretracted Switch

N E G A T I V E :Retracted Switch

P O S I T I V E :Low Level (Pink)

P O S I T I V E :High Level (Red)

Spin 10 Minutes

Thermocycler


Positive Experiences From Key Brewers“The turnaround time with brewPAL made it a no-brainer for us to try it. Knowing that our beer is free of spoilage organisms before it leaves the premises is huge. We can prevent the expense of packaging or bringing beer back to the facility altogether by testing with brewPAL during the brewing process.”– Zach Miller, Yeast and Fermentation Manager, Victory Brewing Company

“As a definitive quality assurance assay with the high sensitivity you need to ensure your beer is free of spoilage bacteria, brewPAL is peace of mind against a potential recall situation.”– Chris Reilly, QA/QC Lab Manager, Weyerbacher Brewing Company

“Bringing the brewPAL and brewLAP microbial system into our brewery is one of the best purchases we have made for our quality assurance testing program. The ability to detect lactic acid bacteria is very important to us in all of the beverages we produce, both alcoholic and non-alcoholic. Having data in a timely fashion allows for better decision making, resulting in improved quality and less loss.”– Rebecca Brandenburg, Director of Quality, The Lion Brewery, Inc.


Invisible Sentinel, a global molecular solutions company, is dedicated to providing first-in-class microbial detection tools. The company’s core technology, Veriflow, is a patented, game-changing platform that integrates molecular diagnostics, antibody

design, and immunoassays. Veriflow has been applied across multiple industries including food safety and beverage quality.

01342 820820 [email protected] www.qclscientific.com

Documents

Best Practices for Quality Testing - QCL Sentinel Handbook copy v4.pdfA PROACTIVE APPROACH TO QUALITY AT YOUR BREWERY. TABLE OF CONTENTS ... Invisible Sentinel has been committed to