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Tully Hadley (MBrew)
Cider Integration into a Large Scale
Commercial Brewery
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 2
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 3
OUTLINE
1. Process Overview
2. Considerations for the Brewery
3. Phase 1 – Blending and Packaging
4. Phase 2 – Fermentation and Clarification
5. Learnings
Project Scope
In 2014 Abbotsford Brewery embarked on a project to develop in house cider fermentation, blending and packaging capability
Objective was to produce a solution that was scalable and flexible enough to produce :
• 12 Existing Apple and Pear Ciders in Cans,
Bottles and Kegs
• NPD ready
• Planning cycle similar to beer
• Meet quality attributes
• Integrate seamlessly with existing
production
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 4
CIDER PROCESS OVERVIEW
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 5
Base Production
Fermentation Filtration Storage Blending Packaging
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 6
Product
Water
Pasteurising
Fermentation
Clarification
Storage
Final
Filtration
Final Product Packaging
Fruit Juice
Concentrate
Fruit Juice
Adjunct
Food Acid
Yeast
Nutrient
Other
Yeast Oxygen
DAW
CO2
Other
Yeast
Propagation
CIDER PROCESS OVERVIEW
PHASE 2
Onsite
Fermentation
and subsequent
processing
PHASE 1
Tankering of
cider base and
subsequernt
packaging
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 7
CONSIDERATIONS FOR THE BREWERY
Dried yeasts are good quality and produce many flavour profiles
Apple Juice lacks essential nutrients for repitching
“Pitch and Ditch” methodology is expensive at large scale.
Hygiene
Dried yeasts specify Lactic Acid bacteria <105 CFU/g
Hygienic Yeast Propagation process is essential
Beware “Killer Factor Active” CIP philosophy to avoid cross contamination
Yeast
Cider is very seasonal – flexible system capacity essential
Easy to automate – continual vs batch
Collect the CO2
Capacity
Maximise existing assets where possible – the process is similar
Cider is acidic – beware of existing civil works
Existing
Assets
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 8
PHASE 1 Raw Material
Receival
• Cider Base
• Juice and
Adjuncts
Raw Material
Storage
• Cider Base
• Juice and
Adjuncts
Blending • Blending
• Dilution
• Carbonation
Packaging • Analysis
• CIP
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 9
PHASE 1 Installation of raw material receival and storage capability
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 10
BLENDING
Existing FV
Existing SV
Existing FV
Existing
BBT
CO2 DAW
Juic
e
Ma
lic
FLA
VO
UR
S
Dilution/Carbonation Storage Cider BBT Dosing Equipment
Diluted and carbonated
through existing filtration
assets
Existing BBT
and controls
are sufficient
Existing storage
assets are
suitable for
storage of cider
Variable viscosity and
flowrate dosing equipment
required for dosing flavours
and aromas
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 11
PHASE 1 Installation of Blending capability
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 12
PHASE 1 Analytical Capability Routine Analysis
Alcohol, SG, PE, RE ( Densitometer)
Colour (Spectrophotomter)
Gravity (Densitometer)
pH (pH meter)
CO2 (CarboQC, cDGM)
Total Acidity (Titrino)
Free SO2 (Titrino)
Total SO2(Titrino)
Ionics – Fe, Cu, Zn, Ca, Mg, K, Na (ICP)
Ionics – Cl, SO4 – (HPLC)
Haze 90⁰ and 25⁰ (Sigrist)
Other Analysis
Volatile Acidity (Gas Chromatography)
Total Fermentable Carbohydrates (HPLC with RI)
Diacetyl (Gas Chromatogrpahy)
Sulphides (GCSCD)
Volatiles (Gas Chromatography)
Sorbitol (HPLC)
Organic Acids - HPLC
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 13
PHASE 2 Fermentation
Base Production
• Blending
• Pastuerising
Yeast Propagation
• Hydration
• Propagation
• Pitching
Fermentation • CO2 Collect
Separation
Clarification •Filtration
•Diafiltration
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 14
FERMENTATION BASE PRODUCTION
Apple Juice FV
Dry yeast
Oxygen
Sterile
H2O
Existing
FV
Additives:
Zinc,
DAP,
Yeast food
Juice
Tanks
Delivery
Yeast Foods Base Pastueriser
Existing FVs
and control
are sufficient.
Unloading to
storage vessel Base is
pastuerised to
ensure sterile
product to yeast
prop and
fermentation.
Cooling and
oxygenation
inline
Juice
Tanks
Yeast nutrients
proportionately
dosed to
predetermined
recipe setpoints
Yeast Injection
Propagated
yeast injected
inline to achieve
recipe pitching
rate
Steam,
refrigerant
Water
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 15
PHASE 2 Fermentation Base production
Proportional Dosing of Yeast Nutrients Flash Pasteuriser for base production
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 16
PHASE 2
Yeast Propagation
For consistency and cost, propagated yeast was favourable
Production cycle is 1 fermenter per week = 1 propagation per week
Traditio al eer yeast propagatio pro ess u suita le
Had to design a yeast propagation process to deliver pitching quantity of cells in a
4000hL fermentation every week.
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section
17
YEAST PROPAGATION
Dry yeast
Oxygen
Sterile H2O
Existing FV
Propagation Rehydration
Cooling with oxygenation
and agitation through
recirculation to build
biomass.
Rehydration of
Dried Yeast, under
aseptic conditions.
O2
Pastuerised
Juice
Pitching
Propagated Yeast is
pitched to achieve recipe
setpoint cell count
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 18
PHASE 2
0
50
100
150
200
250
0 5 10 15 20 25 30
Cells (x 106)
Hours
Yeast Cell Count – Cider Propagation
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 19
PHASE 2
Hydration vessel with:
• CIP and Steam sterilisation
• Laminar flow
• Ozone environmental sanitation
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 20
PHASE 2
Laminar flow conditions to ensure aseptic
conditions
Yeast hydration access hatch – CIP and
steam sterilisation
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 21
PHASE 2
Yeast Propagator Recirculation with online oxygen monitoring
and injection
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 22
PHASE 2
Fermentation
• Uses existing (modified) fermenter vessels
• Normal beer (Ale) fermentation temperatures and pitch rates
• Normal fermentation profile (~200 hrs)
• Yeast is non flocculant
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 23
PHASE 2 DAY
SG°/°C
25
20
12% 15
11%
10%
9%
8% 10
7%
6%
5%
4% 5
3%
2%
1%
0% 0
222 228 234
1.030°
1.085°
1.080°
1.075°
1.700°
1.065°
1.060°
12 174
1.025°
1.055°
1.050°
1.045°
1.040°
1.035°
1.020°
1.015°
1.010°
1.005°
1.000°
0.995°
0.990°
5
18 24 30
6
66
2 3
144 150
4
156 162
0 1
168
1.100°
1.095°
1.090°
108 114 120 126 132 13872 78 84 90 96 10236 42 48 54 60hrs 6
9
ALC
TEM
P
7 8
180 186 192 198 204 210 216
SG
% ALC
Normal fermentation profile with little to no lag phase
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 24
PHASE 2
Cider Membrane Filtration
• Fermented cider base has low protein and polyphenol content
• Chill haze is not an issue
• Cider can be clarified (filtered) once fermentation is complete.
• If using fresh pressed apples, additional treatments are required to clarify.
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 25
PHASE 2
Cider Me ra e Filter to produ e right ider ase
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 26
PHYSICAL PROCESS SEPARATIONS
FERMENTER
Fermenter should be physically isolated on the CO2
Collect and Vent lines to avoid cross contamination into
other fermenters.
STORAGE VESSEL AND BBT CO2 TOP PRESSURE
Top Pressure systems for storage vessels and BBTs were
separated to ensure no flavour carryover between beer
and cider.
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 27
LEARNINGS It is possible to achieve micro free fermentations using dried yeast
Invest in aseptic yeast propagation process
-10
40
90
140
190
240
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Sp
oil
ag
e O
rga
nis
ms
CF
U
Month
Cider Fermentation Spoilage Organisms
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 28
LEARNINGS
• Design in flexibility from the start – innovation is constant
• Fermentation is very reliant upon FAN and nutrient availability
• Extract loss is good – but take note of malic acid
• If treated with the care and attention that we give to beer – great product
quality and product consistency will be the reward.
Acknowledgments
• Sam Seward (Engineering)
• Andy Dzubiel (Engineering)
• Michael Pecar (Engineering)
• Jaideep Chandrasekharan (Chief Brewer)
• Grahame Ellis (Plant Manager, Campbelltown Cidery)
Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 29
IBD PPT – Final Slide
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