21 cost efficient qm in microbreweries agk
TRANSCRIPT
Cost efficient Quality Managementin Microbreweries
Axel G. Kristiansen
Deputy Director DTU Diplom
Danish Technical University
Nordic Meet on Brewing Technology 18th – 20th MAY 2016
Many microbrewer’s Quality Challenges
• Lack of time
• Lack of money
• The microbrewer does every job in the brewery
• Sometimes limited technical and QA knowledge
• Too late, if the customer has to tell, my quality is poor
• Quality is inexpensive, missing quality is costly...
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Definition of Quality
Most people agree, Quality is important, but what is good Quality ?
One definition of quality is:
“Quality is meeting the needs and expectations of customers”
Customers want quality, that corresponds to the price, that they are prepared to pay and the level of competition in the market.
Another definition offered:
‘’Quality is, when the customer returns – not the Beer’’.
Quality may also relate to the consistency in manufacturing meaning, that the brewery is able to produce the same quality brew after brew.
The Quality Hierachy (large brewery)
Useful Terminology for any(micro)brewer
Sample Plan List os samples taken during process: The sampling plan is maybe the most important element of the Quality System !
Recipe List of all ingredients incl. amounts. Does notexplain the manufacturing process.
Process Description
Manufacturing guide to produce a definedamount of product on a defined plant.
Analysis A laboratory’s measurements of contents of certain contents in the product or in rawmaterials. Does not explain the used recipe or process.
Specification The brewery’s limits for which analyticalvalues, we will accept for selected parameters.
Production log The brewery’s registrering of the used processfor each batch, i.e. temperatures, times and volumes.
Declaration The Brewery’s garanti to the consumers and the authorities about certain contents in the final product. Does not explain the used recipe norprocess. 519-05-2016
Example of a production log
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Fermentation control: Temperature and % Plato during fermentation:
Allows the Brewer to spot slow fermentations and when fermentation
has ended. Cost and effort: Almost nothing.
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Days
% P
Before venturing into expensive equipment
1. Am I selling and distributing beer nationwide and with a long shelf life – or selling locally only ?
2. What do I need to measure in the microbrewery ?
3. And which accuracy of measurement do I need ?
4. Basic instruments: Cheap
5. Basic instruments: Costs < 2000 €
6. Portable instruments: Costs > 2000 €
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What makes sense to measure ?
• Chemical parameters (Alcohol, Colour, Bitterness)
• Microbiology (level of infection, pitching yeast standard)
• Raw material checks (malt, hops, glass bottles)
• Flavour (positive flavors and off – flavors)
• Packaging quality (fill level, labelling standards)
• Customer satisfaction (product shelf life)
• Manufacturing logs:
• Raw materials used
• Mashing diagrams
• Fermentation logs
• Samples taken / analysed
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Sara Poyri examining fermentation charts
in a Danish medium size brewery 2012
Example of a Beer chemical Analysis (large brewery)
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Only 7 chemical parameters define the Beer Style and - Quality
1) Original Extract OG [% P] g/100 g
2) Specific Gravity SG [g/ml] 1.00XX
3) Real Extract ER [% P] g/100 g
4) Real Degree of Fermentation RDF [%] g/100 g
5) pH [number]
6) Alcohol by Volume ABV [%] ml/100 ml
7) CO2 [%] g/100 ml
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These 7 chemical parameters can all be measured in the microbrewery by
the microbrewer him/her self
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The microbrewer’s choices
1. What do I need to measure in the microbrewery ?
2. Basic instruments: Cheap
3. Basic instruments: Costs < 2000 €
4. Portable instruments: Costs > 2000 €
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Malt after the mill – often forgotten
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Visual examination of crushed malt enables checks for:
• whole kernels (should not be there !)
•That all kernels are squeezed
• Some flour – not too much
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Brewhouse test: Iodine testShows, whether the mash has converted
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Extract analysis in spent grains:Shows whether we make efficient use of the malt
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Example of home made press Saccharometer
Refractometer:Shows OG of wort
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Refractometer,
hand held
Microbrewer using refractometer
Accuracy: +/- 0.2 % P
Obs.: Other limitations;
but convenient
Refractometer,
Lab. Bench type
The good old SaccharometerShows OG of wort
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Saccharometer Selection of SaccharometersReading af
Saccharometer
Accuracy: +/- 0.1 % P
Use of Saccharometer in practiceas seen in many breweries
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Time consuming – very manual
Pycnometer
Methods with highest accuracy:
Densitometry using Pycnometry
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Accuracy: +/- 0.03 % P
Shows OG of wort
pH – meterShows mash – and wort condition
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Hand held pH - meter Brewers measuring wort pH
Accuracy: +/- 0.1 pH
More Brewhouse tests
Break formation measured
by an Imhoff cone
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For check of efficiency of wort boil: For check of fermentation start:
Wort aeration checked by
a simple flow meter
...and some simple packaging testsmost of these are rarely seen used…
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Humidity test - labels Glue testAir in headspace test
CO2–measurement of bottled beerto ensure same pressure in each bottle
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Quick – not so accurate
Taste testing: A Powerfull Quality – and Diagnostic Tool
Can reveal process defects
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Some times under estimated
for its process diagnostic power
The microbrewers choices
1. What do I need to measure in the microbrewery ?
2. Basic instruments: Cheap
3. Basic instruments: Costs < 2000 €
4. Portable instruments: Costs > 2000 €
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The microscope – cheap, yet powerfull
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Microscope in daily use in one leading
Danish microbrewery’s basic lab.
Acetic Acic bacteria found
In the draft beer from a
Microbrewery
Microscope
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FermentoFlash – example of automaticbeer analysis
• Alcohol (% v/v & w/w)
• Extract – real & apparent
• Original gravity
• Density
• Osmotic pressure
• Degassing of sample
• 10 ml sample
• Analysed in 1 minute
• Printer or PC
• Calibration with reference beer (up to 18 different)
• Prize: ~ 2000 € + VAT
www.funke-gerber.de
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Accuracy: +/- 0.02 % ABV
The microbrewer’s choices
1. What do I need to measure in the microbrewery ?
2. Basic instruments: Cheap
3. Basic instruments: Costs < 2000 €
4. Portable instruments: Costs > 2000 €
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Portable Density Meterto achieve fast and accurate chemical parameters
• Density
• Specific gravity
• Extract
• Alcohol
• Viscosity 0 – 1000 mPa*s
• Temperature compensated 0 – 40°C
Sample: 2 ml
Time: Few seconds
Price: Approx. 2000 €
www.anton-paar.com
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Portable CO2 / DO Measurementto measure Oxygen take – up during production
Anton Paar – CarboQC
www.anton-paar.com
Dr. Thiedig – Digox
www.thiedig.com
Pentair’s CO2 Gehaltemeter
www.Pentair.com
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Several suppliers
Lab. bench Methods – accurate, not cheap
Highest accuracy (do You need it ?)
Densitometry using automatic apparatuses
(most common is PAAR densitometer based on ultrasonic vibrations. The PAAR unit may be a stand-alone or may be built into an automatic complete wort analyzer called a SCAWA)
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Automised micro methods
Aber instruments: Lab Yeast
Analyzer:
Viability by. capasitans
metering
Chemometec: NucleoCounter
viabilitet by Iodine staining
Beckman Coulter: Vi-Cell
viabilitet by Trypan Blue
staining in flow cell
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Customers satisfaction – some times forgotten
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• Do You know, what your customers think
of your beers in trade ?
• Winning beer competitions is nice, but your
everyday customer pays your profit
• Do You systematically collect complaints
statistics and use complaints for process
Improvements ?
Axel G. Kristiansen
Thank you for your attention !
Conclusion:
Quality can be managed and product consistency achieved even in the smallest Brewery for little effort and limited costs !
Back - up
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Type of Chambers for Yeast Cell Count
Haemocytometer with counting chamber type:
• Thomas
• Neubauer or Neubauer improved
• Bürker-Türk
• Malassez
Data for Bürker-Türk:
• Depth: 0.1 mm
• Number of large squares: 9
• Large square area: 1 mm2
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Prepare the Counting Chamber
Representative sample: mix thoroughly
Dilute if necessary
Take up sample with pipette
Cover with cover slip both of the 2 sections
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Count the Cells in the Counting Chamber
Count all 16 small squares in the large square
Count the 2 sections:
• All cells inside the squares
• Include cells touching the left and top boundaries
• Exclude cells touching the right and bottom boundaries
• Budding cells: daughter cells larger than ½ mother cell
• Use the counter – do NOT rely on your memory
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Content of Cold Wort
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Real/Apparent Extract
• Real extract is the amount of carbohydrate measured in weight % Plato.It is measured by measuring the density of the wort/beer (without alcohol) and transformed into %Plato
• Apparent extract is the amount of carbohydrate measured in weight % (% Plato).It is measured by measuring the density of the beer and transformed into %Plato
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Apparent and Real Extract
Real extract
Apparent Extract
Alcohol
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Real Degree of Fermentation
The real degree of fermentation – RDF – is a calculated, not measured, figure expressing the percentage of the extract which has been fermented by the yeast.
• RDF = 100*(OE - ER) / OEOE and ER in % Plato, RDF in %
• Pilsner type beers: RDF is normally 66-72 %
• Low energy/lite beers: RDF can be as high as 85-90 %
• The higher the RDF the more alcohol is formed with the same amount of extract
• A stronger beer can be produced by increasing the Plato and/or increasing RDF
• The RDF is depended on the mashing profile, the type of raw materials, the fermentation method and the use of external enzymes
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Other type O2 Measurement
Dr. Thiedig – Digox
www.thiedig.com
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Flavour & Proces Diagnosis
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47Quality Course for Microbrewers19-05-2016