Implement High Value-Added Quality Control in Breweries with the GeneDisc® System

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Figure 1: The GeneDisc System: GeneDisc Cycler (left) and GeneDisc Plate (right)

OverviewBacterial spoilage risk is a major concern forquality-oriented food and beverage industries as it generates high economic losses and negativelyimpacts brand image. Even though beer is quiterestrictive to bacterial growth due to itscharacteristics (low pH, ethanol concentration, low oxygen content), breweries are no exceptionto this rule. A few bacterial genera, includingLactobacillus, Pediococcus, Pectinatus, andMegasphaera, can cause beer spoilage such asoff-flavors, turbidity or acidity.

Furthermore, growing market demands forminimally processed products (e.g. unpasteurizedand unfiltered craft style beers) or reduced-alcoholbeers, which facilitate growth of spoilage organismsand limit bacterial control measures strengthen theneed for highly effective tools for quality control.

As a result, most breweries have implementedbacterial monitoring throughout their process,

using a testing program unique to each brewery.These programs are mostly based on traditionalculture methods. These methods have a limitedcost- and decision-making effectiveness due totheir limitations:

• They are time-consuming and do not allow anearly warning on contamination.

• They display weak sensitivity when even onesingle spoilage bacteria can cause full batchdamage.

• They are not specific, while bacteria identificationis needed to assess contamination sources andplan for effective countermeasures.

The ChallengeA craft brewery needed to overcome thesetraditional method limitations at identified criticalsampling points. To efficiently control their process,they required faster and informative results. Amongall identified customer’s sampling points, testing

during yeast propagation was extremely critical toavoid bacterial contamination. At this sensitivestep, bacterial infection could have impactedmultiple fermentations. It would also have generatedhigh economic losses to the brewery due toscrapping product, recall, and/or negative brandimage impact.

On the other hand, limited time during yeastpropagation (typically 3 days for this customer)made the use of the traditional method inadequatefor this brewery as results were obtained only afteryeast pitching into the fermenters.

The SolutionTo address the customer’s need for a rapidmethod to monitor and address brewery sourcesof contamination, Pall offers a polymerase chainreaction (PCR) based method using the GeneDiscsystem (Figure 1). This system offers sensitive andspecific detection of major beer spoilage micro-organisms in a matter of hours. This extremelyaccurate tool can be easily implemented in aroutine quality control laboratory. The equipmentautomation ensures reliability and ease of use formicrobiological testing.

With this system, simultaneous detection andidentification of the following 21 major beerspoilage microorganisms is performed at once:

• Lactobacillus brevis

• Lactobacillus lindneri

• Lactobacillus backii

• Lactobacillus collinoides and L. paracollinoides

• Lactobacillus group: L. casei, L. paracasei, L. coryniformis, L. rossiae, L. parabuchneri (= frigidus), L. perolens and L. plantarum

• Pediococcus (P. damnosus, P. inopinatus, P. claussenii)

• Pectinatus (P. cerevisiiphilus, P. frisingensis, P. haikarae, P. portalensis)

• Megasphaera spp. (M. cerevisiae, M. elsdenii)

This highly informative method allows identificationof each spoilage microorganism within 2 hoursafter a single enrichment. It has been validated foruse after enrichment with common broths (e.g.MRS or NBB). The GeneDisc PCR assay is adaptedfor most of the existing sample preparationprocedures used in quality control laboratories andPall also supplies a simplified recommended DNAextraction procedure described in Figure 2.

AfterEnrichment

Transfer 200 µL into aLysis tube. Alternately

some cell material froma single colony.

Transfer the supernatant bypipetting in a bin designatedfor microbiological wastes

Add 600 µL of Dilution Bufferto the bacterial pellet,

close the tube and homogenize (vortex)

Centrifugation5 min at 10,000 g

GeneDisc Ultra-Lyser

Ultrasonic bath8 min at 80%

Heating10 min at 102 °C

Centrifuge15 s

MicrobiologyWaste

Dilution buffer

DNA extract

36 µL

36 µL

Master mix

GeneDisc Plate

Figure 2: Workflow of the GeneDisc Beer Spoilage Bacteria Method

The GeneDisc method is designed for use withvarious sample types including filterable samples(filled product, water) and unfilterable samples(green beer, wort, yeast). The system offers a highvalue-added quality assurance tool in the brewingprocess as it fits into currently implemented testprograms, hazard analysis plans and contaminationtroubleshooting.

The GeneDisc system indicates presence of contamination and it can also be used as aninvestigative tool to precisely identify and trackspecific sources of infection. It facilitates definitionof corrective actions in case of contamination andpreventive measures to avoid reoccurrence of theissue.

Figure 3 shows a selection of some critical pointsidentified in a brewing process where a GeneDisctest can be implemented for routine controls:

Focusing on the customer’s specific concern aboutyeast propagation bacterial quality, implementationof this control point was made possible because ofaccelerated time to results with the GeneDisc Cycler.Results are now obtained in less than 3 days andbefore yeast pitching, while yeast is still in thepropagator. This prevents the use of contaminatedyeast. Furthermore, periodic control of the yeastbrink can also be implemented. The reduced riskof financial losses due to a single or multiple batchspoilage is substantial and justifies a strongrationale for GeneDisc system initial investment.

In addition, breweries can also easily implementinternal environmental testing. With the GeneDiscmethod for Legionella quantification in water (e.g.cooling tower water, tap water), Legionellamonitoring controls can be performed directly atthe production facility.

Mashing

CoolingWort Aeration Fermentation Maturation

Primary Filtration

PVPP Stabilization Trap

FiltrationFine

FiltrationBright Beer Final

FiltrationFilling

YeastManagement

NewYeast

H2O Storage

QualityControl

Quality Control

QualityControl

QualityControl

QualityControl

QualityControl

QualityControl

Lautering Boiling Whirlpool

Figure 3: Examples of GeneDisc Control Points in a Brewing Process

The BenefitsWith the GeneDisc solution, breweries can now achieve high value-added quality control to reducebacterial contamination risk. By implementing Pall’s technology, breweries can realize the followingbenefits:

• Reliable monitoring of all steps of the brewing process

• Accelerated decision-making to reduce risk of product spoilage as GeneDisc technology allowsfor early preventive controls.

• Fast corrective actions implementation to reduce negative financial impact, due to rapid rootcause analysis in case of contamination.

• Easy integration into all brewery types due to proven ease of use. Minimally trained operatorscan achieve reliable and robust results.

About Pall CorporationPall Corporation is a global filtration, separation and purification leader providing solutions to meetthe critical fluid management needs of customers across the broad spectrum of life sciences andindustry. We work with our customers to advance health, safety and environmentally responsibletechnologies.

Pall Food and Beverage provides products and services to ensure product quality and maintainprocess reliability in beverage and food production. Our solutions also assist in consumer protection,the reduction of operating costs and waste minimization.

Pall GeneDisc Technologies

25 Harbor Park DrivePort Washington, NY 11050 +1 516 484 3600 telephone+1 866 905 7255 toll free US

genedisc@pall.com

© Copyright 2015, Pall Corporation. Pall, and GeneDisc are trademarks of Pall Corporation. ® Indicates a trademark registered in the USA. Filtration. Separation. Solution.SM and BETTERLIVES. BETTER PLANET. are service marks of Pall Corporation.

FBABGDBEEREN April 2015

Visit us on the Web at www.pall.com/foodandbev

Pall Corporation has offices and plants throughout the world. For Pall representativesin your area, please go to www.pall.com/contact

Please contact Pall Corporation to verify that the product conforms to your nationallegislation and/or regional regulatory requirements for water and food contact use.

Because of technological developments related to the products, systems, and/orservices described herein, the data and procedures are subject to change without notice.Please consult your Pall representative or visit www.pall.com to verify that thisinformation remains valid.