World Class Manufacturing Session
Daniel Gore, Anton Paar, Graz, Austria
Co-author(s): Keyvan Ghanaviztchi and Peter Brugger, Anton Paar, Graz, Austria
ABSTRACT: Hazard analysis and critical control points
(HACCP), a mainstay in the food industry, has been used in larger
breweries for quite some time and is now a common component of many
quality assurance program. Even smaller breweries, always willing to
implement new ideas, see the advantages HACCP has to offer as part of a
larger quality control program. HACCP is not a stand-alone program and
must be combined with good manufacturing practices (GMP), standard
operating procedures (SOP), and other measures to create a complete
quality assurance program that meshes well with ISO 9001 and
just-in-time (JIT) practices. This poster demonstrates the common
critical control points in the brewery and how combined process and
laboratory instrumentation are used to ensure customer and product
safety and quality control while streamlining production. Traditional,
periodic inspection and sample testing remain the standards with which
all other measurements are compared, forming the base upon which all
safety and quality testing stand, and are an absolute must in the
brewery. They are, however, not as responsive to real-time, production
needs and provide only a snapshot of production. From a public health
and safety, quality control, and customer satisfaction point-of-view,
static production snapshots alone are not enough. In-line process
instrumentation, however, allows for continuous, live process control,
augments laboratory testing, and helps fulfill many HACCP principles in a
single step. The start of any HACCP program is a flow diagram of the
entire brewing process and is specific to the needs of the individual
brewery. After the safety and quality hazards have been analyzed, the
critical control points are identified and appropriate instrumentation
chosen and installed. Once the instrumentation is installed, the
remaining HACCP principles follow logically and are straight forward to
implement: establish critical limits and enter alarm limits into the
instrument control; monitor the critical control points and make process
corrections as needed and as they happen; establish corrective action
to eliminate production errors at control points and follow through when
it is required; keep simple and proper records to monitor quality and
production trends; verify that all the criteria are met; and review the
results to optimize quality and production. After completing the
implementation of a HACCP program and collecting data, optimization
begins to streamline production and trim costs. Known issues are fixed,
and unknown issues may be identified. What may seem at first a daunting
project is actually an organic process that grows with the needs and
focus of the company.
Daniel Gore received his B.A. degree from
the University of Maryland, College Park, including two years of study
in Germany. After graduating in 1995 he returned to Germany and began an
apprenticeship as a brewer and maltster at the Lammbrauerei Hilsenbeck.
After successfully finishing his apprenticeship he worked in multiple
breweries throughout Germany, including the Uerige Obergärige
Hausbrauerei and Quenzer Bräu before moving back to the United States to
assume the role of head brewer at the Long Trail Brewing Company. In
2006 he changed focus to work as a technical sales representative for
Anton Paar, USA and continued to put his 12 years of practical brewing
experience to good use serving the beverage industry. During this time
Daniel was a member of MBAA and ISA and enjoyed working with local
chapters in the Northeast. In 2010 he moved to Graz, Austria, to become
Anton Paar GmbH’s application specialist, supporting Anton Paar’s
existing applications in the beverage industry, as well as developing
new beverage applications and technologies.
VIEW PRESENTATION 225
