MEBAK Microbreweries Table of Contents. Preface Contributors List of Abbreviations Microbreweries... 31

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1 Table of Contents Preface... 3 Information on Purchasing Other MEBAK Volumes... 5 Contributors... 7 List of Abbreviations Microbreweries What is a Microbrewery? Definition The Significance of Microbreweries on the International Market Planning a Microbrewery Market Aspects Business Aspects Business Plan Elements of a Business Plan Meeting with the Bank Sample Profitability Calculation for a Brewpub Brewhouse Model: 10 hl Batch Size, 1,000 hl Annual Capacity Situation at Start-up Sales Projections Cost Estimation Profit and Loss Calculation for the Operation of a Brewpub (GmbH) for One Year What is the Break-even Point for a Brewpub? Final Review Innovative Architecture for Brewpubs

2 MEBAK Microbreweries Table of Contents 1.4 Construction, Technology and Energy Management for Microbreweries General Aspects Emissions and Scent Marketing Master Plan Small Breweries up to 5,000 hl/a Small Breweries over 5,000 hl/a Brewery Planning Building Regulations Local Conditions Building Design Building Plan Equipment Milling Wort Production Automation Fermentation and Lagering Filtration General Information Pre-Coat Filtration Sheet Filtration Filling in a Brewpub or Microbrewery Bottling Kegging Systems Filling Kegs Filling Mini-Kegs Service Units Refrigeration Heat Generation Compressed Air Energy Management Legal Regulations

3 2 Legal and De Facto Aspects of the Term Beer Classification of Beer Types of Beer Beer Styles and Classification in Germany Beer Classification Types of Beer Legal Framework for Producing Beer EU Legislation Quality and Composition of Beer in the EU Reinheitsgebot (German Purity Law for Beer) The German Reinheitsgebot The Bavarian Reinheitsgebot The Munich Reinheitsgebot of Germany Legal Foundation Raw Materials for Brewing and Adjuncts Italy Austria Switzerland Protected Geographical Claims The Taxation of Beer Labeling Guidelines Labeling Elements List of Ingredients Form of the List of Ingredients List of Ingredients for Beer in Germany Labeling of the Basic Ingredients Additives Ingredients Not Requiring Declaration on the Label Ingredients Requiring Declaration on the Label Labeling of Allergens Allergens in Beer Form of the Allergen Labeling

4 MEBAK Microbreweries Table of Contents Quantitative Indication of Ingredients Necessity of the Quantitative Indication of Ingredients Implementation of the Quantitative Indication of Ingredients Net Fill Volume Declaration of Net Fill Volume Permissible Variations The e-mark Best-Before Date (BBD) Definition and Requirement Application of the BBD Storage Instructions Address of the Food Industry Operator Country of Origin or Provenance Instructions for Use Alcohol Content Nutrition Declaration Definition of Nutrition Claims and Nutrition Declarations Form of the Nutrition Declaration Wort and Beer Production in a Microbrewery Allocation and Storage of Raw Materials Brewing Equipment and Operations Milling Mashing Procedures Lautering Acidification with Lactic Acid Produced by Natural Fermentation Wort Boiling Hot Wort Handling Chilling the Wort and Pitching the Yeast Fermentation, Maturation, Lagering and Yeast Handling Fermentation, Maturation, Lagering Brewing Yeast and Yeast Handling Types of Brewing Yeast

5 A Short Description of Two Selected Yeast Strains Wort and Yeast Specifications for a Consistent Performance in Yeast Reproduction and Fermentation Pure Yeast Cultures and Dry Yeast Harvested Yeast Creative Process Engineering in Brewing Spontaneous Fermentation General Information on Spontaneous Fermentation Unintentional Spontaneous Fermentation Intentional Spontaneous Fermentation Combination of Spontaneous Fermentation and Starter Cultures Outlook for the Future Special Hopping Methods Hop Addition: During Mashing, at Mash-Out or use of Steeped Hops Cold Side Hopping and Dry Hopping Explanation of the Term Dry Hopping Reasons for Dry Hopping Wet Hopping with Fresh Hops Conventional Dry Hopping Hop Addition Techniques on the Cold Side of Production Hop Varieties Quantity Transfer Rates for Hop Compounds Stability of the Hop Aroma Considerations in Dry Hopping Sensory Analysis of Dry-Hopped Beers Maturation of Beer on Wood Basic Information in the Selection of Wooden Barrels The Pitching of Beer Barrels The Microbiology of Wooden Barrels Barrel Aging Beer The Methodology, Technology and Logistics of Barrel Aging Design and Construction of a Cellar for Barrel Aging Equipping a Cellar for Barrel Maturation Location as an Important Quality Criterion Selecting Wooden Barrels Preparation for Wooden Barrels for Barrel Aging Beer Filling Barrels

6 MEBAK Microbreweries Table of Contents The Maturation Phase Emptying Barrels Blending Handling Wooden Barrels Single Batches or Consistently Reproducible Products Packaging Barrel-Aged Beers under Special Consideration of Microbiological Aspects Hygiene in a Microbrewery Water Treatment Cleaning/Disinfection Cleaning the Inner Surfaces of Brewhouse Equipment Wort Piping/Wort Chiller Open Fermentation Vessels Closed Fermentation/Maturation Vessels Cleaning and Disinfection of Hoses Miscellaneous Work Clothing Cleaning the Exterior of Vessels, Equipment and Glass Surfaces Water Supply Network Water Hoses Care and Treatment of Fittings Gas Lines Floor Treatment/Drains Cleaning Growlers Cleaning Techniques for Dispensing Systems Dispensing Beer Cleaning Beverage Dispensing Systems The Fundamentals of Cleaning and Disinfection What is Soiling? The Dynamic Nature of Soiling The Microbiological Situation Cleaning Mechanisms The Effects of Mechanical Cleaning The Effects of Chemical Cleaning

7 Components of Cleaning Agents Cleaning Process Cleaning Procedures Cleaning Procedures in Practice Comprehensive Cleaning for Dispensing Systems Regularly Cleaning a Dispensing System Cleaning the Tapping Tubes Demands and Requirements Reasons for Minimum Requirements in Quality Assurance for Microbreweries General Requirements for Microbreweries (Credibility and Crisis Management) Demands on Raw Materials Requirements for Wort and Beer Production Wort Production Beer Production Bottom-Fermented Beers Top-Fermented Beers Filtration and Stabilization Filling Requirements for Cleaning Vessels and Lines Requirements for Dispensing Systems General Legal Requirements Design Requirements Safety Requirements Hygiene Requirements Requirements for Staff Training Other Requirements Requirements Pertaining to the Quality and Composition of Beer

8 MEBAK Microbreweries Table of Contents 6 Quality Control Basic Laboratory Equipment Chemical-technical Laboratory Microbiological Laboratory Quality Control Recommended Minimum Scope of Testing Chemical-technical Analysis Sensory and Visual Quality Control of Beer Visual Quality Control at the Brewery Microbiological Analysis Raw Material Specifications Recommendations Water Grain Malt Alternative Raw Materials Containing Starch Specifications for Hops and Hop Products Yeast Example of a Complete Quality Control Program for a Mid-sized Brewery

9 Analysis Methods Chemical-technical Analysis Water Sample Collection Odor and Taste Color Determination of Color Visual Method Clarity (Turbidity) Method Using a Transparent Cylinder Method Using a Secchi Disk ph Value Conductivity Hardness Definition Total Hardness Carbonate Hardness Acid Consumption (Alkalinity, p and m Values) Acid Capacity up to ph 8.2 or Malt Barley Malt Sample Collection Visual Inspection Physical and Physiological Tests for Barley Malt Endosperm Character Glassy Kernels Color Determination of Friability with a Friabilimeter (EBC) Acrospire Development Sieving Test Physico-chemical Analysis Moisture Content (EBC) Extract (EBC) Odor of the Mash (EBC) Iodine Test/Saccharification Rate (EBC) Filtration (EBC) Appearance ph Value (EBC) Wort Color, Visual Determination (EBC) Nitrogenous Substances

10 MEBAK Microbreweries Table of Contents Total Nitrogen, KJELDAHL Method (EBC) Soluble Nitrogen, KJELDAHL Method (EBC) Specialty Malts Moisture Content (EBC) Extract in Roasted and Caramel Malt (EBC) Color of Roasted and Caramel Malt (EBC) Color of Liquid Malt Coloring Agent Visual Method Spectrophotometric Method Acidulated Malt ph Titration Acidity L-Lactic Acid/D-Lactic Acid (EBC) Wheat Malt Adjuncts Sample Collection Moisture (EBC) Extract Extract, De Clerck Method (EBC) Extract, ASBC Method (EBC) Extract, Enzymatic Method for Corn (EBC) Extract, ASBC Method for Liquid Adjuncts (EBC) Total Nitrogen/Protein Fat Content (Free Crude Fat) (EBC) Color (EBC) Gelatinization Temperature Whole Hops and Pellets Sample Collection Manual Evaluation of Whole Hops Wort and Beer Sample Collection Odor and Flavor of Wort Visual Iodine Test Degree of Attenuation Limit of Attenuation in Wort (Fermentation Tube Method) Limit of Attenuation in Wort and Beer Reference Method (EBC) Limit of Attenuation in Wort and Beer Rapid Method (EBC) Attenuation of Maturing and Finished Beer

11 Original Gravity and Alcohol Degassing a Sample Density Measurement Hydrometer Oscillating U-tube Density Measurement (EBC) Apparent Extract (EBC) Distillation Analysis Reference Method (EBC) Refractometric Analysis Multifunctional Devices Oscillating U-tube Density and NIR Measurements Thermal Analysis Method FermentoStar Color Visual Determination by Comparison ph Turbidity Visual Method Optical Method Bitter Substances Bittering Units (EBC) iso-α-acids and α-acids (Spectrophotometry) Foam Foam Stability Visual Method Foam Stability, NIBEM Foam Stability, Lg-Foam Tester Foam Stability, Steinfurth Foam Stability Tester Carbon Dioxide Manometric Methods Measuring Device for Carbon Dioxide in Tanks or Lines, Haffmans Rapid Determination of Carbon Dioxide in Bottled Beer, STADLER and ZELLER CO2 Measuring Device, Steinfurth System Carbon Dioxide in Bottled Beer, ZAHM and NAGEL Carbon Dioxide in Packaged Beverages or At-line with CarboQC, Anton Paar Sensory Analysis Raw Materials Processing Aids, Operating Supplies and Additives Filter Aids and Stabilizing Agents Aroma Flavor Lactic Acid (Food-Grade Lactic Acid) Activated Charcoal

12 MEBAK Microbreweries Table of Contents Intermediate Products Wort Lactic Acid Produced by Natural Fermentation Green Beer Final Products Evaluation of Individual Beer Samples DLG Quality Assessment for Beer Doemens Score Sheet Labor Veritas Score Sheet Tasting Scheme for Wheat Beers According to HERRMANN and SACHER Microbiological Analysis Brewery Microbiology, Standard Values, Basic Equipment and Principles Microbreweries General Information on Microbiology Reference Values and Critical Values Definitions Reference Values, Limit Values and Standard Values for Beer Method Matrices for Determination of Reference Values, Limit Values and Standard Values for Beer Basic Microbiology Equipment and Procedures General Microbiological Methods Dilution Series Pour Plate Technique Spread Plate Technique (Spread Plates with Spatula) Weighted Arithmetic Mean Microbiological Methods for Detecting and Identifying Certain Groups of Microbes in the Brewery for Comparison to Standard, Reference and Critical Values Total Cell Count, Mesophiles at 28 C Enterobacteriaceae Coliforms Method A Coliforms Method B (according to AGES) Escherichia coli Yeast and Molds Beer-spoiling Bacteria Methylene Blue Staining of Bacteria and Yeast Determining Cell Count with a Counting Chamber Methods, Types of Samples and Sample Collection Schedule for Routine Microbiological Quality Control General Aspects/Sample Collection Comprehensive Microbiological Quality Control according to JACOB Simplified Microbiological Quality System (MQS)

13 List of Tables List of Figures List of Advertisers

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1.4.2 Germinative Energy Germinative Energy AUBRY Method (EBC) Germinative Energy SCHÖNFELD Method (EBC) Table of Contents Preface to the New Edition... 3 Information about the MEBAK Website... 4 Contributors... 5 Table of Contents... 7 List of Abbreviations... 16 1 Barley... 14 1.1 Sample Collection... 16