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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