Episode 171: Best Practices - Container Rinsing with Water
Feb 12, 2024
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A team of Master Brewers discusses best practices for container rinsing with water in breweries. They highlight the importance of real-time data analysis, rinse water specifications, and monitoring rinse nozzles and valves. The podcast also emphasizes the significance of product safety, routine cleaning, and monitoring programs for water quality.
Proper rinsing of bottles and cans in breweries is crucial to ensure product safety and should include fail-safe mechanisms to prevent improperly rinsed containers from being filled.
The design of the rinser, water supply specifications, maintenance, and validation procedures all play a crucial role in the effectiveness of rinsing bottles and cans in a brewery setting.
Deep dives
Importance of Proper Rinsing for Product Safety
Proper rinsing of bottles and cans in breweries is crucial to ensure product safety. The main objective of rinsing is to remove foreign objects and substances that could impact the quality of the beer or pose a safety hazard. These can include lubricants, chemical residue, dust, glass particles, plastic, insects, and more. Rinsing with clean water helps to eliminate these contaminants before the containers are filled. It is essential to have fail-safe mechanisms, such as pressure cut-out switches or pointer gauges, to detect low flow or pressure conditions and shut down the line to prevent improperly rinsed containers from being filled and shipped. Regular verification procedures, including checking nozzle functionality, monitoring microorganisms, and verifying fail-safe mechanisms, should be incorporated into standard operating procedures.
Factors Affecting Rinsing Effectiveness
Various factors can impact the effectiveness of rinsing bottles and cans in a brewery setting. The design of the rinser plays a crucial role, including the type of nozzle material and design, as well as the draining properties of the rinser. It is important to have proper water supply specifications, including the use of potable water and the avoidance of introducing sanitizers that may taint the beer. In some cases, reusing water in the rinsers can be cost-effective, but it requires regular validation and filtration to remove microbiological contaminants. Maintaining proper supply pressure and flow meters, as well as implementing shut-off valves for emergencies or testing, is essential. Adequate shielding before and after the rinser, along with regular cleaning to prevent biofilm growth, should also be prioritized.
Validation and Quality Control Measures
Validating the effectiveness of rinser operations is crucial to ensure proper rinsing. This can be done through seat tests using potential physical hazards, such as glass, wood, plastic, insects, or cardboard, to verify their removal during rinsing. Validation should be performed at the lowest operating pressure or flow to ensure effective rinsing under suboptimal conditions. Regular verification procedures should be incorporated into daily operations, including visual checks of nozzle functionality and monitoring of microorganisms and sanitizer concentrations. It is important to have fail-safe mechanisms in place to detect low flow or pressure conditions and shut down the filler to prevent the filling of incompletely rinsed containers. Regular cleaning and inspection of the rinser, as well as maintaining proper draining properties, should be part of the cleaning protocols in the brewery.
Cleaning and Maintenance of Rinsers
Proper cleaning of rinsers is vital to maintain their functionality and prevent contamination. It is important to regularly inspect and clean the rinsers, including removing plexiglass shields for thorough cleaning behind them. If water reclaim systems are in place, the vessels collecting reclaimed water should be regularly drained and cleaned to prevent the growth of microorganisms. Ensuring good water quality through routine monitoring and the use of ATP swabs or microplating techniques can help determine cleaning schedules and identify any potential issues with the rinser. Adequate drainage and shielding before and after the rinser should be maintained to prevent foreign objects from entering the filler room or contaminating the containers.
Does your brewery can or bottle? Do you pay close attention to your rinser or just assume it does what it's supposed to? This week on the show, we take a deep dive into water rinsers with a team of Master Brewers who collaborated to publish a Best Practices document you can use to get bottle and can rinsing done right.
Special Guests: Ben Bailey, Dave Duff, Eric Samp, Heather Muzzy Caron, and Tim Lozen.