Program Book - Master Brewers Association of the Americas

P-121
Improved plant cleanliness, productivity, and efficiency
through the application of ozone-injected water in plant
sanitation processes
CHRIS ROMBACH (1), Robert Smith-McCollum (1)
(1) Pacific Ozone, Benicia, CA
Ozone, the tri-atomic form of oxygen (O 3 ), is a gas that is formed
when diatomic oxygen (O 2 ) is exposed to high voltage electric
fields or UV radiation. Ozone is an unstable molecule due to
the weak bonds holding the third oxygen atom, making ozone a
naturally powerful oxidizing and disinfecting agent. Established
commercial applications for ozone include municipal water
treatment, groundwater remediation, electronics manufacturing,
commercial laundry, as well as sanitation processes in the fresh
produce packing, food processing, winery, beverage, and bottled
water industries. Ozone can be applied in commercial breweries in
water purification and wastewater processing as well as a variety of
sanitation processes, including surface sanitization, clean-in-place
(CIP) sanitation of tanks and piping, and bottle and cap rinsing
during filling. Our analysis of these applications reveals significant
potential for greater plant cleanliness and overall productivity and
efficiency. Plant cleanliness is enhanced by the superior oxidizing
and disinfecting capabilities of ozone-injected water. Our analysis
of the implementation of a cold ozone CIP system in a large bottling
plant demonstrated improved microbiological results, significant
savings of chemicals and energy, and greater plant efficiency. After
installation, ozone CIP was progressively adapted to nearly threequarters
of the typical CIP runs. Microbiological testing revealed
the three-step ozone CIP process to be more effective than a 5-step
hot detergent CIP process. Microbiological tests for ozone CIP
were 97% negative versus 81% negative for hot CIP. Our analyses
also indicate significant potential increases in plant efficiency and
productivity through the effectiveness of ozone-injected water at
lower temperatures than traditional CIP protocols. Cold ozone
CIP saves energy and chemicals and reduces the brewery’s carbon
footprint. Annual energy and chemical cost savings were $72,000
and nearly $300,000, respectively. Plant productivity was increased
by significant reductions in sanitation process times and the
elimination of CIP temperature ramp-up periods. The CIP run time
was reduced by two-thirds from three hours to one hour. This time
savings yielded an increase in overall plant efficiency of 4.1%, which
represents an additional production of six million cases of product
per year.
Chris Rombach is the president of Pacific Ozone, a world leading
supplier of ozone generation and application systems for the food,
beverage, pharmaceutical, and industrial markets. Rombach holds
a B.S. degree in biology from Humboldt State University. He has
over 15 years of experience in design and sales of filtration, fluid
handling, CIP, and water treatment equipment to the food, beverage,
and biopharmaceutical industries. Rombach joined Pacific Ozone in
2006.
126
P-122
Improvement of the mashing process by means of vibration
sources in mash kettles
FRANK-JUERGEN METHNER (1), Ralph Schneid (2), Christopher
Nueter (1)
(1) TU Berlin/VLB Berlin, Germany; (2) Krones AG Steinecker
Plant, Freising, Germany
Brewhouse work is continually improved by technical and
technological developments. As a result of increasing raw material
and energy prices, attempts have been made to optimize the yield
and reduce evaporation during wort boiling. In these efforts, the
quality of the wort still has top priority. During the mashing process,
vibration sources now are used to intensify the technological
procedures. The vibration generator basically is an electric
unbalanced motor, which can produce frequencies in a range of
0–200 Hertz. Soluble oxygen in the mash, which is mainly added
during mashing-in, can be reduced by the vibrations. This causes
fewer oxidation processes, which improves, among others, the aging
stability of the finished beer. Depending on the concentration of the
first wort, there is an ideal frequency range to activate the mash to a
resonance vibration, thereby enhancing substance transport of the
malt contents from malt particles to the fluid phase of the mash. It
has been proven that there are more enzymes dissolved from the raw
material, which causes quicker and more intensive extract formation
in the mash. The intensified substance transport of course effects a
higher yield, which can be proven, for example, by the convertible
extract in spent grains. Enzymatic activity is increased by vibrations
in the mashing process. The mechanical energy input causes an
increased motion in the enzymes and substrate. As a result, more
enzymatic catalyses are possible for each period of the mashing
program, which allows a reduction of mashing time. In addition to
the two classic parameters, rest period and rest temperature, there
now is a new possibility to affect wort quality by means of the brew
master.
From 1975 to 1981, Frank-Juergen Methner studied brewing science
at the Technical University of Berlin (TU). After these studies,
he began working as an operating supervisor at the Schlosser
Brewery. From 1982 to 1986 he worked as a scientific assistant with
teaching duties at the Research Institute for Brewing and Malting
Technology of VLB in Berlin. His research projects and Ph.D. thesis,
“Aroma Formation of Berliner Weissbier with Special Focus on
Acids and Esters,” were additional tasks. For 18 years, starting in
1987, Methner held a leading position as a director at the Bitburg
Brewery, Bitburg, Germany, with responsibilities in fields such as
technology and quality management. Beginning with the winter
semester 2004/2005, he took over the chair of brewing science at
TU and is currently the head of the Research Institute of Technology
for Brewing and Malting of the Research and Teaching Institute
for Brewing (VLB). Since 2005 he has been vice-chair of the EBC
Brewing Science Group.