Table of Contents Preface... 3 Information on Purchasing Other MEBAK Volumes... 5 Contributors... 7 List of Abbreviations... 11 1 Microbreweries... 31 1.1 What is a Microbrewery?... 31 1.1.1 Definition... 31 1.1.2 The Significance of Microbreweries on the International Market... 32 1.2 Planning a Microbrewery... 35 1.2.1 Market Aspects... 35 1.2.2 Business Aspects... 36 1.2.2.1 Business Plan... 36 1.2.2.1.1 Elements of a Business Plan... 36 1.2.2.1.2 Meeting with the Bank... 38 1.2.2.2 Sample Profitability Calculation for a Brewpub... 40 1.2.2.2.1 Brewhouse Model: 10 hl Batch Size, 1,000 hl Annual Capacity... 40 1.2.2.2.1.1 Situation at Start-up... 40 1.2.2.2.1.2 Sales Projections... 41 1.2.2.2.1.3 Cost Estimation... 41 1.2.2.2.1.4 Profit and Loss Calculation for the Operation of a Brewpub (GmbH) for One Year... 43 1.2.2.2.1.5 What is the Break-even Point for a Brewpub?... 44 1.2.2.2.1.6 Final Review... 45 1.3 Innovative Architecture for Brewpubs... 47 17
MEBAK Microbreweries Table of Contents 1.4 Construction, Technology and Energy Management for Microbreweries... 53 1.4.1 General Aspects... 53 1.4.2 Emissions and Scent Marketing... 57 1.4.3 Master Plan... 58 1.4.3.1 Small Breweries up to 5,000 hl/a... 58 1.4.3.2 Small Breweries over 5,000 hl/a... 61 1.4.3.2.1 Brewery Planning... 61 1.4.3.2.2 Building Regulations... 63 1.4.3.2.3 Local Conditions... 64 1.4.3.2.4 Building Design... 64 1.4.3.2.5 Building Plan... 66 1.4.4 Equipment... 69 1.4.4.1 Milling... 69 1.4.4.2 Wort Production... 70 1.4.4.3 Automation... 72 1.4.4.4 Fermentation and Lagering... 73 1.4.4.5 Filtration... 74 1.4.4.5.1 General Information... 74 1.4.4.5.2 Pre-Coat Filtration... 76 1.4.4.5.3 Sheet Filtration... 78 1.4.5 Filling in a Brewpub or Microbrewery... 80 1.4.5.1 Bottling... 80 1.4.5.2 Kegging Systems... 86 1.4.5.2.1 Filling Kegs... 87 1.4.5.2.2 Filling Mini-Kegs... 90 1.4.6 Service Units... 91 1.4.6.1 Refrigeration... 91 1.4.6.2 Heat Generation... 91 1.4.6.3 Compressed Air... 92 1.4.7 Energy Management... 92 1.5 Legal Regulations... 93 18
2 Legal and De Facto Aspects of the Term Beer... 95 2.1 Classification of Beer... 95 2.2 Types of Beer... 96 2.3 Beer Styles and Classification in Germany... 97 2.3.1 Beer Classification... 97 2.3.2 Types of Beer... 98 2.4 Legal Framework for Producing Beer... 102 2.4.1 EU Legislation... 102 2.4.2 Quality and Composition of Beer in the EU... 104 2.4.3 Reinheitsgebot (German Purity Law for Beer)... 106 2.4.3.1 The German Reinheitsgebot... 106 2.4.3.2 The Bavarian Reinheitsgebot... 108 2.4.3.3 The Munich Reinheitsgebot of 1487... 109 2.4.4 Germany... 110 2.4.4.1 Legal Foundation... 111 2.4.4.2 Raw Materials for Brewing and Adjuncts... 113 2.4.5 Italy... 119 2.4.6 Austria... 120 2.4.7 Switzerland... 126 2.5 Protected Geographical Claims... 128 2.6 The Taxation of Beer... 128 2.7 Labeling Guidelines... 129 2.7.1 Labeling Elements... 130 2.7.2 List of Ingredients... 131 2.7.2.1 Form of the List of Ingredients... 132 2.7.2.2 List of Ingredients for Beer in Germany... 132 2.7.2.3 Labeling of the Basic Ingredients... 132 2.7.2.4 Additives... 135 2.7.2.5 Ingredients Not Requiring Declaration on the Label... 139 2.7.2.6 Ingredients Requiring Declaration on the Label... 139 2.7.3 Labeling of Allergens... 140 2.7.3.1 Allergens in Beer... 140 2.7.3.2 Form of the Allergen Labeling... 141 19
MEBAK Microbreweries Table of Contents 2.7.4 Quantitative Indication of Ingredients... 142 2.7.4.1 Necessity of the Quantitative Indication of Ingredients... 142 2.7.4.2 Implementation of the Quantitative Indication of Ingredients... 143 2.7.5 Net Fill Volume... 144 2.7.5.1 Declaration of Net Fill Volume... 144 2.7.5.2 Permissible Variations... 145 2.7.5.3 The e-mark... 146 2.7.6 Best-Before Date (BBD)... 147 2.7.6.1 Definition and Requirement... 147 2.7.6.2 Application of the BBD... 148 2.7.7 Storage Instructions... 148 2.7.8 Address of the Food Industry Operator... 149 2.7.9 Country of Origin or Provenance... 149 2.7.10 Instructions for Use... 150 2.7.11 Alcohol Content... 150 2.7.12 Nutrition Declaration... 151 2.7.12.1 Definition of Nutrition Claims and Nutrition Declarations... 151 2.7.12.2 Form of the Nutrition Declaration... 152 3 Wort and Beer Production in a Microbrewery... 157 3.1 Allocation and Storage of Raw Materials... 161 3.2 Brewing Equipment and Operations... 162 3.2.1 Milling... 163 3.2.2 Mashing Procedures... 163 3.2.3 Lautering... 165 3.2.4 Acidification with Lactic Acid Produced by Natural Fermentation... 166 3.2.5 Wort Boiling... 167 3.2.6 Hot Wort Handling... 167 3.2.7 Chilling the Wort and Pitching the Yeast... 168 3.3 Fermentation, Maturation, Lagering and Yeast Handling... 169 3.3.1 Fermentation, Maturation, Lagering... 169 3.3.2 Brewing Yeast and Yeast Handling... 172 3.3.2.1 Types of Brewing Yeast... 174 20
3.3.2.2 A Short Description of Two Selected Yeast Strains... 175 3.3.2.3 Wort and Yeast Specifications for a Consistent Performance in Yeast Reproduction and Fermentation... 179 3.3.2.4 Pure Yeast Cultures and Dry Yeast... 181 3.3.2.5 Harvested Yeast... 183 3.4 Creative Process Engineering in Brewing... 185 3.4.1 Spontaneous Fermentation... 185 3.4.1.1 General Information on Spontaneous Fermentation... 187 3.4.1.2 Unintentional Spontaneous Fermentation... 188 3.4.1.3 Intentional Spontaneous Fermentation... 189 3.4.1.4 Combination of Spontaneous Fermentation and Starter Cultures... 192 3.4.1.5 Outlook for the Future... 193 3.4.2 Special Hopping Methods... 196 3.4.2.1 Hop Addition: During Mashing, at Mash-Out or use of Steeped Hops... 197 3.4.2.2 Cold Side Hopping and Dry Hopping... 197 3.4.2.2.1 Explanation of the Term Dry Hopping... 198 3.4.2.2.2 Reasons for Dry Hopping... 199 3.4.2.2.3 Wet Hopping with Fresh Hops... 199 3.4.2.2.4 Conventional Dry Hopping... 201 3.4.2.2.4.1 Hop Addition Techniques on the Cold Side of Production... 202 3.4.2.2.4.2 Hop Varieties... 212 3.4.2.2.4.3 Quantity... 216 3.4.2.2.4.4 Transfer Rates for Hop Compounds... 218 3.4.2.2.4.5 Stability of the Hop Aroma... 219 3.4.2.2.4.6 Considerations in Dry Hopping... 219 3.4.2.2.4.7 Sensory Analysis of Dry-Hopped Beers... 220 3.4.3 Maturation of Beer on Wood... 223 3.4.3.1 Basic Information in the Selection of Wooden Barrels... 223 3.4.3.2 The Pitching of Beer Barrels... 231 3.4.3.3 The Microbiology of Wooden Barrels... 232 3.4.3.4 Barrel Aging Beer... 232 3.4.3.4.1 The Methodology, Technology and Logistics of Barrel Aging... 233 3.4.3.4.1.1 Design and Construction of a Cellar for Barrel Aging... 233 3.4.3.4.1.2 Equipping a Cellar for Barrel Maturation... 235 3.4.3.4.1.3 Location as an Important Quality Criterion... 235 3.4.3.4.1.4 Selecting Wooden Barrels... 236 3.4.3.4.1.5 Preparation for Wooden Barrels for Barrel Aging Beer... 237 3.4.3.4.1.6 Filling Barrels... 238 21
MEBAK Microbreweries Table of Contents 3.4.3.4.1.7 The Maturation Phase... 239 3.4.3.4.1.8 Emptying Barrels... 240 3.4.3.4.1.9 Blending... 240 3.4.3.4.1.10 Handling Wooden Barrels... 241 3.4.3.4.1.11 Single Batches or Consistently Reproducible Products... 241 3.4.3.4.2 Packaging Barrel-Aged Beers under Special Consideration of Microbiological Aspects... 242 4 Hygiene in a Microbrewery... 243 4.1 Water Treatment... 243 4.2 Cleaning/Disinfection... 247 4.2.1 Cleaning the Inner Surfaces of Brewhouse Equipment... 250 4.2.2 Wort Piping/Wort Chiller... 250 4.2.3 Open Fermentation Vessels... 251 4.2.4 Closed Fermentation/Maturation Vessels... 253 4.2.5 Cleaning and Disinfection of Hoses... 254 4.3 Miscellaneous... 255 4.3.1 Work Clothing... 255 4.3.2 Cleaning the Exterior of Vessels, Equipment and Glass Surfaces... 255 4.3.3 Water Supply Network... 256 4.3.4 Water Hoses... 256 4.3.5 Care and Treatment of Fittings... 257 4.3.6 Gas Lines... 258 4.3.7 Floor Treatment/Drains... 258 4.3.8 Cleaning Growlers... 259 4.3.9 Cleaning Techniques for Dispensing Systems... 260 4.3.9.1 Dispensing Beer... 260 4.3.9.2 Cleaning Beverage Dispensing Systems... 260 4.3.9.3 The Fundamentals of Cleaning and Disinfection... 261 4.3.9.3.1 What is Soiling?... 261 4.3.9.3.2 The Dynamic Nature of Soiling... 262 4.3.9.3.3 The Microbiological Situation... 264 4.3.9.4 Cleaning Mechanisms... 265 4.3.9.4.1 The Effects of Mechanical Cleaning... 265 4.3.9.4.2 The Effects of Chemical Cleaning... 266 22
4.3.9.4.3 Components of Cleaning Agents... 266 4.3.9.4.4 Cleaning Process... 267 4.3.9.4.5 Cleaning Procedures... 267 4.3.9.5 Cleaning Procedures in Practice... 268 4.3.9.5.1 Comprehensive Cleaning for Dispensing Systems... 268 4.3.9.5.2 Regularly Cleaning a Dispensing System... 269 4.3.9.5.3 Cleaning the Tapping Tubes... 269 5 Demands and Requirements... 271 5.1 Reasons for Minimum Requirements in Quality Assurance for Microbreweries... 271 5.2 General Requirements for Microbreweries (Credibility and Crisis Management)... 271 5.3 Demands on Raw Materials... 272 5.4 Requirements for Wort and Beer Production... 276 5.4.1 Wort Production... 276 5.4.2 Beer Production... 277 5.4.2.1 Bottom-Fermented Beers... 277 5.4.2.2 Top-Fermented Beers... 277 5.4.2.3 Filtration and Stabilization... 278 5.4.3 Filling... 278 5.5 Requirements for Cleaning Vessels and Lines... 278 5.6 Requirements for Dispensing Systems... 278 5.6.1 General... 278 5.6.2 Legal Requirements... 280 5.6.3 Design Requirements... 281 5.6.4 Safety Requirements... 286 5.6.5 Hygiene Requirements... 287 5.6.6 Requirements for Staff Training... 287 5.6.7 Other Requirements... 288 5.7 Requirements Pertaining to the Quality and Composition of Beer... 288 23
MEBAK Microbreweries Table of Contents 6 Quality Control... 290 6.1 Basic Laboratory Equipment... 290 6.1.1 Chemical-technical Laboratory... 290 6.1.2 Microbiological Laboratory... 290 6.2 Quality Control Recommended Minimum Scope of Testing... 291 6.2.1 Chemical-technical Analysis... 291 6.2.2 Sensory and Visual Quality Control of Beer... 292 6.3 Visual Quality Control at the Brewery... 294 6.4 Microbiological Analysis... 294 7 Raw Material Specifications Recommendations... 295 7.1 Water... 295 7.2 Grain... 295 7.3 Malt... 296 7.4 Alternative Raw Materials Containing Starch... 305 7.5 Specifications for Hops and Hop Products... 306 7.6 Yeast... 310 8 Example of a Complete Quality Control Program for a Mid-sized Brewery... 312 24
Analysis Methods... 321 Chemical-technical Analysis... 321 Water... 321 Sample Collection... 321 Odor and Taste... 323 Color... 326 Determination of Color Visual Method... 326 Clarity (Turbidity)... 327 Method Using a Transparent Cylinder... 327 Method Using a Secchi Disk... 328 ph Value... 328 Conductivity... 330 Hardness... 332 Definition... 332 Total Hardness... 335 Carbonate Hardness... 338 Acid Consumption (Alkalinity, p and m Values)... 339 Acid Capacity up to ph 8.2 or 4.3... 339 Malt... 341 Barley Malt... 341 Sample Collection... 341 Visual Inspection... 343 Physical and Physiological Tests for Barley Malt... 345 Endosperm Character... 345 Glassy Kernels... 345 Color... 345 Determination of Friability with a Friabilimeter (EBC)... 346 Acrospire Development... 349 Sieving Test... 351 Physico-chemical Analysis... 353 Moisture Content (EBC)... 353 Extract (EBC)... 355 Odor of the Mash (EBC)... 360 Iodine Test/Saccharification Rate (EBC)... 360 Filtration (EBC)... 361 Appearance... 361 ph Value (EBC)... 362 Wort Color, Visual Determination (EBC)... 364 Nitrogenous Substances... 366 25
MEBAK Microbreweries Table of Contents Total Nitrogen, KJELDAHL Method (EBC)... 366 Soluble Nitrogen, KJELDAHL Method (EBC)... 370 Specialty Malts... 372 Moisture Content (EBC)... 372 Extract in Roasted and Caramel Malt (EBC)... 373 Color of Roasted and Caramel Malt (EBC)... 375 Color of Liquid Malt Coloring Agent... 376 Visual Method... 377 Spectrophotometric Method... 378 Acidulated Malt... 379 ph... 379 Titration Acidity... 379 L-Lactic Acid/D-Lactic Acid (EBC)... 381 Wheat Malt... 386 Adjuncts... 386 Sample Collection... 387 Moisture (EBC)... 387 Extract... 390 Extract, De Clerck Method (EBC)... 390 Extract, ASBC Method (EBC)... 393 Extract, Enzymatic Method for Corn (EBC)... 396 Extract, ASBC Method for Liquid Adjuncts (EBC)... 398 Total Nitrogen/Protein... 399 Fat Content (Free Crude Fat) (EBC)... 400 Color (EBC)... 402 Gelatinization Temperature... 404 Whole Hops and Pellets... 408 Sample Collection... 408 Manual Evaluation of Whole Hops... 409 Wort and Beer... 414 Sample Collection... 414 Odor and Flavor of Wort... 415 Visual Iodine Test... 415 Degree of Attenuation... 416 Limit of Attenuation in Wort (Fermentation Tube Method)... 416 Limit of Attenuation in Wort and Beer Reference Method (EBC)... 419 Limit of Attenuation in Wort and Beer Rapid Method (EBC)... 421 Attenuation of Maturing and Finished Beer... 422 26
Original Gravity and Alcohol... 424 Degassing a Sample... 425 Density Measurement... 426 Hydrometer... 426 Oscillating U-tube Density Measurement (EBC)... 427 Apparent Extract (EBC)... 428 Distillation Analysis Reference Method (EBC)... 430 Refractometric Analysis... 433 Multifunctional Devices... 436 Oscillating U-tube Density and NIR Measurements... 437 Thermal Analysis Method FermentoStar... 439 Color Visual Determination by Comparison... 440 ph... 442 Turbidity... 445 Visual Method... 445 Optical Method... 446 Bitter Substances... 448 Bittering Units (EBC)... 448 iso-α-acids and α-acids (Spectrophotometry)... 451 Foam... 454 Foam Stability Visual Method... 454 Foam Stability, NIBEM... 455 Foam Stability, Lg-Foam Tester... 460 Foam Stability, Steinfurth Foam Stability Tester... 462 Carbon Dioxide Manometric Methods... 463 Measuring Device for Carbon Dioxide in Tanks or Lines, Haffmans... 464 Rapid Determination of Carbon Dioxide in Bottled Beer, STADLER and ZELLER... 465 CO2 Measuring Device, Steinfurth System... 467 Carbon Dioxide in Bottled Beer, ZAHM and NAGEL... 468 Carbon Dioxide in Packaged Beverages or At-line with CarboQC, Anton Paar... 469 Sensory Analysis... 472 Raw Materials... 472 Processing Aids, Operating Supplies and Additives... 472 Filter Aids and Stabilizing Agents... 472 Aroma... 472 Flavor... 473 Lactic Acid (Food-Grade Lactic Acid)... 474 Activated Charcoal... 475 27
MEBAK Microbreweries Table of Contents Intermediate Products... 475 Wort... 476 Lactic Acid Produced by Natural Fermentation... 478 Green Beer... 481 Final Products Evaluation of Individual Beer Samples... 483 DLG Quality Assessment for Beer... 483 Doemens Score Sheet... 487 Labor Veritas Score Sheet... 488 Tasting Scheme for Wheat Beers According to HERRMANN and SACHER... 489 Microbiological Analysis... 491 Brewery Microbiology, Standard Values, Basic Equipment and Principles.. 492 Microbreweries General Information on Microbiology... 492 Reference Values and Critical Values Definitions... 492 Reference Values, Limit Values and Standard Values for Beer... 493 Method Matrices for Determination of Reference Values, Limit Values and Standard Values for Beer... 498 Basic Microbiology Equipment and Procedures... 501 General Microbiological Methods... 503 Dilution Series... 503 Pour Plate Technique... 504 Spread Plate Technique (Spread Plates with Spatula)... 505 Weighted Arithmetic Mean... 506 Microbiological Methods for Detecting and Identifying Certain Groups of Microbes in the Brewery for Comparison to Standard, Reference and Critical Values... 507 Total Cell Count, Mesophiles at 28 C... 507 Enterobacteriaceae... 509 Coliforms Method A... 510 Coliforms Method B (according to AGES)... 512 Escherichia coli... 514 Yeast and Molds... 515 Beer-spoiling Bacteria... 517 Methylene Blue Staining of Bacteria and Yeast... 519 Determining Cell Count with a Counting Chamber... 521 Methods, Types of Samples and Sample Collection Schedule for Routine Microbiological Quality Control... 522 General Aspects/Sample Collection... 522 Comprehensive Microbiological Quality Control according to JACOB... 523 Simplified Microbiological Quality System (MQS)... 523 28
List of Tables... 547 List of Figures... 551 List of Advertisers... 555 29