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TRANSCRIPT
BY NATHAN SANBORN AND HALEY CAMPBELL RISING TIDE BREWING COMPANY
Quality Control for the Little Folk: SIMPLE THINGS THAT SMALL BREWERIES CAN DO TO
HAVE CONFIDENCE IN THEIR BEER
Overview
● History of Rising Tide Brewing Co. ○ Experience of a Beer Recall ○ Our Early Program
● Why QA/QC? ● QA/QC Program ○ Standard Operating Procedures ○ Record Keeping and Traceability ○ Data Analysis ○ Sensory Program ○ Laboratory Work
● Costs, Time Requirements, and Difficulty
A Quick History
A Quick History
● Founded October 2010 ● 12 yrs homebrewing
experience ● 1 BBL nano ● 145 bbls first full year
A Quick History
● Expanded spring 2012 ● 15 bbl brewhouse ● 2x30, 1x7 FVs ● First hires ● First beer shipped out of
state ● 500 bbls in 2012
Experience of a Beer Recall
● Just before New Year’s 2014, <<RING RING>>: Broken Ursa Minor bottles in the market
● Testing showed refermentation in the bottles
● Recall? Recall. ● Going out of business?
Our Early Program
● Standardized procedures ● Testing of solutions ● Sensory ● Basic lab analysis ○ Forced fermenations ○ Wort stability ○ Beer spoilers
Original Business Plan QA/QC
Why QA/QC?
Why QA/QC?
● COMPETITION ● RESPONSIBILITY ● CONFIDENCE
Our QA/QC Program
● Standard Operating Procedures (SOPs) ● Record Keeping and Traceability ● Data Analysis ● Sensory Program ● Laboratory Work
Standard Operating ProceduresI’ve been
brewing for 8 years and I still have to check
the SOPs!
Standard Operating Procedures
● Every task at the brewery should have a written SOP, and the SOPs should be organized and easily accessible to all.
Record Keeping & Traceability
Record Keeping & Traceability
● Well-organized, informative record keeping procedures are necessary to promote real-time and long-term quality
A second person signs off on the malt for each batch
Mash data including panel vs sample temps
Batch data for traceability
Final runnings & kettle gravity, volume, pH
Kettle additions
Whirlpool and KO dataGravity/pH to FV
Tracking actual times throughout the brew process is important data.
Sheet is designed to capture all the important data.
Organized around the way OUR brew process runs.
Record Keeping & Traceability
Mark weighed and milled. Jared checked the weights. Questions? We know with whom to check.
Spence averaged temps from 3 samples. Mash temp was 2 degrees low from target. Will inform expected attenuation.
No final runnings data. Why?
Efficiency well off expected. Too much sparge water remaining in MLT? Slightly higher than optimal pH? Lower mash temps? We have data to compare to other brews.
Record Keeping & Traceability
Yeast information is recorded for every batch
Forced ferment results can be useful on certain batches
Expected cellar schedule is listed here.
Graph of gravity over time allows you to see how fermentation is progressing
Record Keeping & Traceability
Cell counts and viability are done in the lab and did not get transferred here. Missing data!
Regular cell counts of fermenting beer are a goal but out of reach at this time due to time constraints. House yeast beers are very predictable, however.
Diacetyl test results. More on this later.
This is a very typical fermentation curve for our IPA. We can easily compare batches visually and we monitor the progress of these curves closely.
Record Keeping & Traceability
Record Keeping and Traceability
• Yeast brinks all have detailed coding
Record Keeping & Traceability
Beer Library ● A physical record of all
your beer with identifiable coding over the course of its shelf-life
GOOD
WHAT?
● How important is record keeping and traceability? ● With UM recall, first reported data was sketchy,
appeared to indicate batch 176. ● Batch 176 tested within spec. ● Suspected bad glass, got glass supplier involved. ● Wait… More reports…. Better batch data… The
batch was actually 168.
Record Keeping & Traceability
UM 13-1 168 10/7/13
● Packaged gravity was 1.018 ● Tested at -1.005 s.g. from package gravity ● RECALL!
Record Keeping & Traceability
Data Analysis
QUARTER
Data Analysis
FERMENTATION LENGTH BY SEASON
Data Analysis
DAYMARK AMERICAN PALE ALE
URSA MINOR WEIZEN STOUT
Days
Spec
ific
Gra
vity
Days
Spec
ific
Gra
vity
Fermentation Profiles
Cell
coun
t (m
illio
ns)
Generation
Data Analysis
Sensory Program
Sensory Program
Goals ➢ True to Type (TTT) recognition ➢ Off-flavor recognition and identification ➢ “Rising Tide” character familiarity ➢ Ingredient familiarity ➢ Discover (in)sensitivities and personal preference
Sensory Program
Implementation ➢ Training ➢ Dedication ➢ Repetition ➢ Variety ➢ Feedback and reward
Sensory Program
Materials ● Beer! ● Off-flavor kits ○ Siebel Institute of
Technology ○ Aroxa ○ FlavorActiv ○ Make your own
● Information ○ ASBC, MBAA, literature,
other breweries
Laboratory Work
Laboratory Work
Wort Sterility Test ● A sterile sample taken
from the heat exchanger that is incubated or allowed to sit at room temperature and visually examined for any signs of fermentation
Laboratory Work
Cell Counting ● The single most important
thing you can do for your beer!
Laboratory Work
COUNTING CELLS IS EASY!
Laboratory Work
Gravity/Temperature/ pH Monitoring
● Should be done on every fermenting beer every day!
Laboratory Work
VDK Force Test ● Heat a sample of beer that
has reached terminal gravity, cool it back down, and assess for diacetyl aroma.
The beer has the final say on when we proceed…
…not the sales or accounting departments!
Laboratory Work
Dissolved Gas Monitoring ● Zahm & Nagel make different CO2
detection devices ● A few different companies
sell dissolved oxygen meters suitable for breweries
Laboratory Work
Selective & Differential Media ● Many different media that
you can prepare yourself, or buy pre-poured.
Laboratory Work
Selective and Differential Media
● Hsu’s Lactobacillus and Pediococcus (HLP) medium
Outsourcing and “In”sourcing
● White Labs’ Big QC Day
• Brewing and Distilling Analytical Services, LLC
• Alpha Analytics®
Costs, Time Requirements, and Difficulty
● Most of what we discussed today is quick and easy to perform or implement and requires little special equipment beyond what you already have.
● The exceptions are worth the extra time, money and effort
Costs, Time Requirements, and Difficulty
● Get your record keeping in order! FREE! Minimal ● Sensory! $250 30 min/session
○ Beer, spikes kit, pitcher(s)
● Wort Stability! $50 30 sec/brew ○ Whirl Pak sterile sample bags
● Cell counting! $300 10 min/count ○ Microscope, hemacytometer, pipettes, meth blue, test tubes
● Beer spoilers! $400 45-60 min/week ○ HLP media, sterile test tubes and pipettes, (enough for 700 tests!)
hot plate, graduated cylinders, flasks, beakers
Then build from here!
TASK COST TIME
What to do with a $1000 budget?
In conclusion…
If you have the finances to open a brewery and the
knowledge and skills to brew beer, you can develop a QC program. Start building your program now!
Thank you!
● Questions? Comments?
● Feel free to contact either of us in the future Nathan: [email protected] Haley: [email protected]