Post on 20-Jan-2016
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MICROBREWQuality Control and Beer Science at Jack’s Abby Brewing
Kate Steblenko
Jack’s Abby Brewing• Started in 2011
• 2011 – 500 bbls• 2012 – 1,500 bbls • 2013 – 6,000 bbls• 2014 – 14,000 bbls• 2015 – 22,000 bbls• 2016 – 50,000 bbls?
• New Brewery opening this winter• ~5X bigger• Lab space 60 ft2 270 ft2
The New Space
Jack’s Abby Instagram
QA/QC TEAMThe highest in quality
Kate SteblenkoBeer Scientist
• UVM 2013 graduate
• BS in Biochemistry and molecular genetics
• Resident nerd
Tim WilsonQuality Manager
• Siebel Institute of Technology & Doemens Academy – 2007
• Runs sensory program
• Enjoys Corona
Sarah PottQA/QC Technician
• Part time kegger
• Part time lab rat
• Full time push up champion
• Graduate of Drop-In’s American Brewers Guild program
TasksDaily
•Forced fermentations
•Cell counts•Microbiology•Fill heights•Dissolved Oxygen
Weekly/Monthly
•Sensory Education
•Grist analysis
Forced Fermentations•Naturally carbonated beers•Bung timing •Batch to batch consistency•Wort quality•Yeast health
Cell CountsCurrent
• Adequate pitch• Lager – 1.5 x 107 cells/ml/
• Underpitching and overpitching
• Yeast health, growth, and viability
Future• Yeast propagation system
• Slurry counting• Appropriate pitch
• 1.5 x 106 cells/ml/°P OG
• Flow meter on prop system pitch exact volume needed
Microbiology Media
• HLP• Anaerobic in 15 ml conical
tubes• Detects lactobacillus and
pediococcus
• WLN/WLD• Brewery related
organisms• Add cycloheximide to
inhibit Saccharomyces species
Frequency• Sampling
• Day 1• Day 7• Brite tank• Finished Product
• Plating• Every 1-2 days
Aseptic Technique• You do not NEED a sterile hood! (although it REALLY helps!)
• Requires an undisturbed air space• Limit movement in the
air space as well as people moving around it
• Flame everything
http://files.shroomery.org/files/13-20/874348262-Aseptic_Convection.gif
Plating – Past and PresentPast
• Plate 1 mL of beer in process onto large petri dish
• Allow time to soak into plate• Filter ~25 ml packaged
beer through a 0.45 µM membrane• Use autoclavable, glass
filtration system
• Invert and incubate 4-6 days at 30°C, 10% CO2
Present
• Filter 10 ml of beer in process through a 0.45 µM membrane
• Biosart 100 monitors• Plate onto small petri dish• Invert, incubate
anaerobically 4-6 days at 30°C, 10% CO2
Anaerobic Incubation SystemsBD GasPak™ EZ Container
System BD GasPak™ EZ Pouch System
www.bd.com
A busy day in
the hood
Fill Heights•At least 3 months of data for TTB•Use weights, final gravities, and math•Adjust filler accordingly
• Underfill – unsellable• Overfill – loss of product• Total Packaged Oxygen
Dissolved Oxygen• Centrifugation
• Adjust clamps, gaskets
• Before bottling• Compare to post centrifuge levels• Assess oxidation levels• Purge with extra CO2
• Throughout the bottling run• Adjust FOB
Sensory• Monthly sensory training• Off flavors• Warm aged bottles from
time-points over the past few months
• Employee education
www/pinkbootssoiety.com
Grist Analysis•Analyze each new silo delivery•Test sieve
• USA Standard test sieve• No. 10 (2.00 mm) – No. 100 (150 µm)
•Still establishing specs
Sizing up the ProgramOut with the old In with the new!
Our First Investment
Tuttnauer 2450Fits 4-6 500 ml media bottles
Future Improvements • Liquid media
• Saves time, money, resources• Only works with Biosart 100 monitors
• Larger hood space• Less turbulence • More room to move• Permanent hood installation
• Manifold for vacuum pump• Multiple samples at once
New Lab, New Tools• UV-Vis Spectrophotometer
• IBU• Color• Diacetyl
• Alcolyzer• Alcohol percentage• Density• pH• Calories
• Dissolved O2 and CO2 meters
uk.hach.com
www.antonpaar.com
ca.hach.com
Cheers!Kate Steblenko
kates@jacksabbybrewing.com