Packaging Quality
Wednesday, June 4 - 10:00 a.m.-11:45 a.m.
Lobby Level, Empire Ballroom
Rob Fraser, Sierra Nevada Brewing Co.; Chaz Benedict, Hach Company; Shawn Theriot, Deschutes Brewing Co.; Rebecca Newman, Dogfish Head Brewing Co.
Current packaging quality methods of analysis are out-of-date due to time and new technologies both in the lab and in production. Also, evolving raw materials give quality and production personnel many challenges to ensure package integrity and quality. This workshop will focus on sharing current packaging quality challenges as well as reviewing and sharing current best practices for quality analysis of packaging materials, finished products, and processes ranging from receiving to palletizing for bottling, canning, and kegging. Technical speakers will share insights and best approaches for packaged gas measurements. The workshop will provide participants insight, learning, and awareness of approaches to packaging quality.
Scribe Notes
- The importance of using a Total Package Oxygen (TPO) measurement versus only a Dissolved Oxygen (DO) or Air measurement for quality control testing of packaged beer was highlighted.
- Oxygen damage has a cumulative effect from the brewhouse to packaging.
- Cover gas flow rate is more important than pressure for reducing TPO in cans. (Flow rate per package).
- If a brewery cannot afford a Total Package Oxygen Analyzer it is possible to estimate the TPO using DO, Headspace Volume, Beer temperature, and the volume of beer in the package.
- Glass melts between 2600 – 2800F and is cooled to 2100F prior to entering the forming machines.
- Top 3-defects of glass are stones, disrupted loads and split finishes.
- Saving defects is a great way to help increase your glass bottle quality. Defects are added to the glass plants library and are then used as challenge samples.
- Breweries should have specifications and Acceptable Quality Limits for their bottles
- Sierra Nevada Brewing Company (SNBCO) uses Statistical Process Control to determine which vent tube to use with the bottles as the molds age. This helps to maintain proper fill level and reduces beer loss during the filling process. Traceability and FIFO are key to making this process work.
- Every brewery needs to have a burst bottle program to protect consumers from glass contamination. This consumer safety program needs to be both verified and validated.
Malt Analytical Laboratories Discussion and Workshop
Wednesday, June 4 - 1:00 p.m.-2:45 p.m.
Lobby Level, Empire Ballroom
Organizer: Scott Heisel, American Malting Barley Association
Xiang Yin, Cargill Malt; Yueshu Li, Canadian Malting Barley Technical Center; Bruno Vachon, Malterie Frontenac Inc.; Paul Schwarz, North Dakota State University
This workshop will cover the current state of malt analysis in North America. It will focus on the requirements of a growing craft brewing and malting industry and whether existing technologies and facilities meet the needs. Invited speakers related to these different areas of expertise will share their knowledge in what we expect to be a very interactive discussion. Participants will be asked to get creative and share their ideas and experiences with malt analysis. The workshop’s primary purpose is to gauge the interest in having such a service and what types of tests are of interest.
Scribe Notes
- Malt analysis involves physical, chemical, and biochemical measures and is used by maltsters for process and quality control, as well as product specification.
- Methods have evolved over the years, with changes in understanding and technology. Standard procedures are maintained by organizations such as the ASBC (North America), EBC (Europe), BCOJ (Japan), and MEBAK (Germany).
- Modern testing methods involve the use of specialized equipment such as programmable laboratory mashing baths, digital density meters, and segmented flow instrumentation which can be costly, but increase efficiency and precision through automation.
- The number of craft maltsters is increasing rapidly in North America. These companies specialize in producing artisan malts in small batches from primarily locally grown grains.
- Their small size and limited resources can make obtaining malt analysis challenging. However, it is possible to obtain meaningful and reliable information on malt quality using a few modifications and some creativity.
- Near infrared spectroscopy is a widely used tool in the agriculture and food industries, and questions often arise about it usefulness for predicting malt quality.
- While parameters such as moisture and protein can be predicted with high accuracy, calibrations for others such as extract and enzymes are generally only suitable for rough screening (i.e. plant breeding applications). Creating robust calibrations also requires that sample libraries include appropriate range of variation in genetics and environment.
Sensory Workshop—How to Get to the Next Level
Wednesday, June 4 - 3:00 p.m.-4:45 p.m.
Lobby Level, Empire Ballroom
Lindsay Guerdrum, New Belgium Brewing Co., Sue Thompson, MillerCoors; Ian McLaughlin, Craft Brew Alliance; Teri Horner, MillerCoors
This workshop is designed for those who already have their feet wet in running a sensory program. Experts in the field will discuss the next steps one can take when growing a taste panel. Topics will include advanced techniques like descriptive analysis in relation to shelf life, raw material sensory analysis, threshold testing, and running a sensory program in a multi-facility brewery.
Scribe Notes
- Baseline for panels is >10 panelists experienced and confident, trained and validated,
- There are 3 primary sensory tests: Discrimination, difference, and descriptive analysis and that test method must match the objective.
- Descriptive analysis is primarily used for describing products and how they relate to other products. Not to be used for product release. If difference testing finds a difference then DA can provide nature and degree of differences. Some examples of where it is helpful include: Brand fingerprinting, raw material evaluation and correlation to analytical measurements.
- The main statistical tools used to interpret the data are: Principal Component analysis, partial least squares and clustering. Used to show relationships between multivariables.
- Panels need to be validated to ensure accurate results. Validation includes: 1) repeatability – ability to score same over multiple reps., 2) sensitivity: ability to detect differences between products and agreement, panelist is able to agree on the panel, 3) Reproducibility – able to be conducted across multiple products, breweries etc.
- The threshold of an individual is the geometric mean of last incorrect concentration in series of ascending triangle tests. Geometric mean is used as a central tendency measurement because it resists skewing due to outliers.
- Importance of standardization and randomization is key to reproducibility, repeatability and meaningful results. Protocol, test methods, scaling, environment are examples of factors that should be standardized.
Food Safety I
Thursday, June 5 - 10:00 a.m.-11:45 a.m.
Level 4, Grand Ballroom
Patrick Staggs, Crown Beverage Packaging; Patricia Pratt, MillerCoors; Rob Fraser, Sierra Nevada Brewing Co.; Chuck Eckermann, MillerCoors; Johannes Tippmann. TU Munchen
With the recent passage of the Food Safety Modernization Act (FSMA), food manufacturing facilities, including those in the brewing industry, will be required to comply with applicable food laws. Seven Proposed Rules have been published within the Regulatory Framework of FSMA. All seven will be published in final form by the end of June 2015. Being prepared is not only important for compliance but is also good due diligence. As brewers, we have an obligation to our consumers to ensure that the beers we produce are safe and within the guidelines of food safety and regulatory requirements.
The goal of this two-part workshop is to help you prepare to meet this obligation. It will provide an update on the first, second, and fourth proposed FSMA law, “Rules for Current Good Manufacturing Practice and Hazard Analysis and Risk-Based Preventive Controls for Human Food,” specifically its inclusion of spent grains from brewers, as well as “Current Good Manufacturing Practice and Hazard Analysis and Risk-Based Preventive Controls for Food for Animals.”
In this first part of two, the workshop will cover the overall state of the industry, FDA regulations, shifting cultural behaviors, and mastering a cleaning schedule. This workshop will outline important components of a food safety program for brewers. Do not miss Part II on Friday for more!
Scribe Notes
- All industry members are responsible for shielding the consumer from harm through the installation of food safety programs at each of their facilities.
- Installation of food safe practices not only protects the consumer, but is conducive to protecting the brand and perception of the industry.
- Selective pressures for increased surveillance of the food industry have arisen not only from regulatory agencies, but also from the consumer population.
- The pressure for food safety reform has been driven by increased incidences of food contamination in recent years. As a result, regulations such as FSMA have now impact the brewing industry as well.
- MBAA Food Safety Committee has made available materials to assist brewers, of all sizes, in developing adequate food safety programs specific to the brewing industry.
Turning Data into Information to Make Decisions—“The Science of Beer” in an Information Age
Thursday, June 5 - 2:00 p.m.-3:45 p.m.
Lobby Level, Empire Ballroom
Fred Strachan, Sierra Nevada Brewing Co.; John Engel, MillerCoors; Gina Shellhammer, GSJ Consulting
Is your brewery drowning in data yet starved for information? In an ever-changing world of data and information within our breweries and throughout our supply chains, the speed of data conversion into actionable information and knowledge is critical to our businesses. This interactive workshop will explore the use of various types of data generated within the brewing process to enhance quality programs. In addition, the theory and practical use of Statistical Process Control will be examined as a quality tool in various areas of the brewery. There will be plenty of time for Q&A with your colleagues as this workshop promises to provide practical instruction and discussion on a subject that is top-of-mind for brewing scientists around the world.
Food Safety II
Friday, June 6 - 8:00 a.m.-9:45 a.m.
Level 4, Grand Ballroom
Ron Vail, AIB; Shawn Theriot, Deschutes Brewery; Tatiana Lorca, Ecolab, Inc.
The goal of this two-part workshop is to help you prepare to meet the obligation of the FSMA. We will cover “Current Good Manufacturing Practice and Hazard Analysis and Risk-Based Preventive Controls for Human Food,” specifically its inclusion of spent grains from brewers, as well as “Current Good Manufacturing Practice and Hazard Analysis and Risk-Based Preventive Controls for Food for Animals.”
In this second part of two, the workshop will cover HACCP, verification vs. validation, and business cases and auditing. In addition, a lively discussion with a brewery food safety expert will guide you through preparing for a successful food safety audit from the U.S. Food and Drug Administration (FDA).
You will walk away from this workshop knowing the components of an effective food safety program that you can put into action immediately. Join us as we share the key to how you can change your brewery culture to enable a successful food safety program.
Scribe Notes
- The goal of the second part of the workshop was to further expand on the ideas discussed during the first session as well as introduce many systems that can be used by a brewer to certify and validate their process using audits.
- It is crucial to maintain a close relationship with supplier to encourage good practices and the importance of CGMPs.
- The concepts of verification and validation were detailed as they pertain to a HACCP plan. The core concepts of what HACCP is and how it can be a benefit to the brewer was also provided.
- A summary of the GFSI, BRC, SQF, FSSC, and IFS and how these systems can increase the safety and marketability of the products you may create were given.
