BY JOSEPH S PICKETT

DEFINING & SOLVING PROBLEMS IN MODERN DRAFT BEER LINE CLEANING. TSUNAMI - A GREEN SOLUTION UTILIZING MECHANICAL ACTION.

JOSEPH S PICKETT MASTER BREWER • CREATOR OF TSUNAMI

• PIONEERED MICROBREWERIES SINCE 1980

• SENIOR MANAGEMENT FOR G. HEILEMAN BREWERIES,

PABST BREWING CO. & OWNED - PICKETT BREWING COMPANY

• STAFF MEMBER OF THE SIEBEL INSTITUTE OF BREWING

• CHAIRMAN OF THE MASTER BREWERS ASSOCIATION

TECHNICAL QUARTERLY WITH JEFF COORS

40 PLUS YEARS IN THE BREWING INDUSTRYCURRENTLY : EXECUTIVE DIRECTOR OF BREWING ELLIS ISLAND CASINO & BREWERY

OVER 800,000 GLASSES OF DRAFT BEER ARE SOLD EACH YEAR.

BEER LINES ARE 200 TO 300 FEET LONG • THERE ARE 47 TAPS &

4,6OO FT OF DRAFT BEER LINES

Tsunami will ensure the best quality draft beer for customers. It will save time and money while reducing the use of harsh chemicals.

Tsunami is the first major improvement in line cleaning since the circulation pump. Not just a pump, it is a cleaning system; it is the most advanced beer line cleaning system in the market. It is only system that will remove all loose soil. The only beer line cleaning system that will attack beerstone. The only system that amplifies mechanical action to a point where it will remove any and all biofilm. A system that does not require turbulent flow to create wall shear. The only system that has the ability to safely take your line cleaning to four weeks or more. The intensified mechanical action associated with this system will take cleaning to a new level.

BY JOSEPH S PICKETT

40 PLUS YEARS IN THE BREWING INDUSTRYCURRENTLY : EXECUTIVE DIRECTOR OF BREWING ELLIS ISLAND CASINO & BREWERY

OVER 800,000 GLASSES OF DRAFT BEER ARE SOLD EACH YEAR.

BEER LINES ARE 200 TO 300 FEET LONG • THERE ARE 47 TAPS &

4,6OO FT OF DRAFT BEER LINES

DEFINING AND SOLVING PROBLEMS IN MODERN DRAFT BEER LINE CLEANING.THE TSUNAMI CLEANING SYSTEM, A GREEN SOLUTION UTILIZING MECHANICAL ACTION.

There is a consumer awareness for cle-

an draft beer lines. The consumer’s are

demanding quality products from beer

taps that do not produce off flavors or

sediments. To keep draft beer as the fi-

nest beverage an adult can enjoy, new

and advanced cleaning methods must be

employed.

The draft systems used today are many

times longer and more sophisticated

than the systems in the past. The cle-

aning technology has not kept up with

these new systems.

In developing a new cleaning strategy for

draft beer lines it is prudent to evaluate

the cleaning procedures and techniques

currently in use. Cleaning procedures

require a more in-depth understanding

of the soil, how it attaches to the beer

line, the composition of the soil, the vari-

ous techniques of soil removal and a re-

alistic evaluation of the present long line

systems.

In the past several years long line tech-

nology has become dominate. The re-

mote location of beer kegs rather than, “

the old under the bar systems”, has been

increasing. The length of these installa-

tions can be over 400 feet and the na-

ture of these installations (40 to 80 in-

dividual brands on tap) has caused more

cleaning problems and more problem

awareness.

Currently, more and more effort is being

put into draft beer quality. Draft beer for

a retailer is a major profit center. It is a

sampling point and sales outlet for beer

producers. There is a conscious on going

effort beer companies are making to ser-

ve the customer the very best product.

There is an effort made by retail outlets

to be certain that their own standards

and requirements for great draft beer

are satisfied.

Draft beer quality standards begin with

proper design of the installation. Coo-

ler management (temperature, and pro-

duct rotation), the quality of the gas

used to pressurize the keg. The pumps

used to move the beer through the beer

lines. The cleaning and proper serving

techniques of the beer glass itself. All of

these conditions being perfect; the beer

line delivering the beer is crucial. This is

because of the surface to product cont-

act ratio is magnified 25 times for every

100 feet of beer line, as compared to the

surface to product contact of a keg.

The physical and biological cleanliness

of these lines is critical to the frequency

of cleaning as it affects the taste, physi-

cal appearance, and foam quality of the

product being served.

Introduction

The beer line delivering the beer is crucial. This is because of the sur-face to product contact ratio is magnified 25 times for every 100 feet of beer line, as compared to the surface to product contact of a keg.

DEFINING AND SOLVING PROBLEMS IN MODERN DRAFT BEER LINE CLEANING.THE TSUNAMI CLEANING SYSTEM, A GREEN SOLUTION UTILIZING MECHANICAL ACTION.

ICEBERG.MEDIA.

In current draft system installations there

have been many improvements over the

past years. It would be noteworthy to men-

tion some of those improvements.

The publication of the draft beer manual by

the Brewers Association.

There have been major improvements in the

composition of the beer lines. Permeability,

liners, and oxygen absorption.

The requirement to use a cleaning circulati-

on pump in lines of more than 25 feet. This

effort has been employed to create turbul-

ent flow as defined by Reynolds number.

Unfortunately, these numbers lose signifi-

cance when the diameters of the lines beco-

me smaller and this method does not have

the capacity to lift out the solid soils.

Cleaning with sponges is good, but it has li-

mitations.

There have been major improvements in the

chemical composition of beer line cleaning

materials and the awareness of the correct

usage of such products.

There have been improvements in the insu-

lation and refrigeration equipment used in

draft beer dispensing.

There have been improvements in the sani-

tary design of beer spigots. All of the above

items have gone to improve the quality of

draft beer.

There has been a resurgence of what is

termed “passive mechanical systems”.

Electrical forces, magnetic forces, ul-

trasound and other items of some na-

ture claiming to slow down the deposi-

tion of soils, but the soils still physically

attach to the walls of the beer line. The-

se systems may be effective but there

is no substitution for proper cleaning.

Proper cleaning should be the major

focal point before using or rating there

proper effectiveness.

The use of a water rinse between kegs

will do what it is intended to do and that

is rinse. There should be no misunder-

stand that the only thing a water rinse

will do is rinse. It will not clean.

DRAFT BEER LINE SYSTEMS

Installations& Improvements

Beer line installations are built for the convience of design and never for the consideration of cleaning. This maze of lines are anywhere from 100 to 400ft long & contain numerous bends and corners that go up down walls and through ceilings.

RESTRICTION

LOCATIONUP

A 1

2F

T W

AL

L

UNDERGROUND DRAFT LINE

CEILING OR OVERHEAD

DRAFT LINE

UP

A 1

2F

T W

AL

L

UP

A 1

2F

T W

AL

L

25O FTBBQ LINEUP A 12FT WALLRUNS THE CEILING WITH TURNSDROPS DOWN TO CHOKE POINT

Lines going down then up walls and inside ceilings,

left then right numerous times are all of the requirements

for installation, but they create areas and pockets for soil

accumulation. Dips in the lines mean soil deposits at the

low areas, due to the density of the soils. The use of various

line sizes, and with multiple branchesto feed multiple locations.

Beer line installations have restrictions installed to raise pressure

in order to decrease foaming and stabilize the beer.

RESTRICTION

LOCATION

RE

ST

RIC

TIO

NLO

CA

TIO

N

RESTRICTION

LOCATION

RESTRICTION

LOCATION

All of these techniques are designed to

restrict flow, and with present cleaning

techniques flow is necessary to clean.

To further complicate the issue, there is

a limit as to how much pressure the lines

are designed to take. The recommended

pressure limit is 60 psi. There is a direct

relationship between flow, pressure and

line diameter. For example in a 3/8”

draft beer line there may be a 3/16” re-

striction, therefore when measuring flow

in a beer line, the flow will be that of a

3/16” line not a 3/8” line at a given pres-

sure. Add to that the increased surface

area due to the additional line length and

proper cleaning is difficult.

Once the installation is complete, the cle-

aning and maintenance of the system be-

gins. This responsibility ultimately falls

on the venue for the life of the system.

EXAMPLES AND PROBLEMS WITH

Restrictions

www.tsunami.works

A thorough cleaning is extremely difficult using techniques developed for short line runs. Placing restrictions on the flow from in-itial design techniques, then trying to achie-ve maximum flows for cleaning thru a maze of lines with restrictions makes correct clea-ning virtually, impossible.

DRAFT BEER LINE Flow Restrictors

PLACING RESTRICTIONS ON THE FLOW FROM INITIAL DESIGN

TECHNIQUES, THEN TRYING TO ACHIEVE MAXIMUM FLOWS FOR

CLEANING THRU A MAIZE OF LINES MAKES CORRECT CLEANING

VIRTUALLY, IMPOSSIBLE

THE COMPOSITION OF THE

In recent literature cleaning lines weekly was

recommended. Quote: “There is no debate

the best practice is to clean every week”. (1)

In other studies it was shown that there was

explosive biological growth after two weeks.

When asking a brewery, ”What is the shelf life

of your draft beer?” Most will answer, “Our

draft beer is good for 60 days.”

This fact is difficult to understand. If the beer is

clean and good for 60 days, why do we clean

every two weeks? The only logical explanation

is the beer line has not been properly cleaned.

In an article written by two renowned brewing

scientists, finally there is a recognition of the

existence and presence of biofilms. Quote:

“And biofilms are a major threat to the product

quality of draft beer.” (2) This article is a reco-

gnition that there is biofilm in draft beer lines.

It is an excellent explanation of what biofilm is

and the properties of biofilm. It fortifies the

need for an advanced cleaning method that

can deal with this newly recognized form of

contaminant in beer lines. It also recognizes

that these soils do not appear or function as

individual soil components, but as an intertwi-

ning mass with all of the soils solidly connec-

ted. Ultimately, this is the fact will explain why

in the past, cleaning was required every week

and why the lines have never been totally cle-

aned.

,

Beerstone is a uniquely structured bio-film protected by a fortress of calcium oxlate cyrstals that are glued together by polysaccharides. It is an imperme-able and inpentrable structure that harbors debris and organisms which are detrimental to beer quality.The beer industries unique form of biofilm, held together by exacellu-lar polysaccharides, the “glue” that binds calcium oxalate, protein, hop resins, carbohydrates, other mineral crystals and microorganisms into a defined structure.

,

WHAT IS

Beerstone?

SOILS

Beerstone is a uniquely structured bio-film protected by a fortress of calcium oxlate cyrstals that are glued together by polysaccharides. It is an impermeab-le and inpentrable structure that harbors debris and organisms which are detri-mental to beer quality.

THE CALCIUM OXALATE

CRYSTALS ADHERING TO EACH OTHER.

THIS IS ACTUAL BEER LINE SOIL.

MAGNIFIED 1000X IMAGE BY PICKETT

THE BIRTH OF

Beerstone

Once beerstone is established it is the most

difficult material to remove. Experienced

brewers will attest to that fact. The most

harsh and dangerous chemicals have to be

used to remove this material in breweries.

Quote: This material in a beer line will dictate

a one or two week cleaning to just control its

further development. (3)

Beerstone removal from a draft beer line re-

quires a new technology. The calcium oxala-

te crystal portion of the beerstone is neutral

in charge and is very dense once formed.

Beerstone has been proven to be the harbor

for beer spoilage organisms. The calcium

oxalate crystals are an integral part and pro-

tector of the biofilm structure and unless it is

removed totally, the lines will require cons-

tant and frequent cleaning to just maintain.

The physical properties of beerstone (beer

biofilm) make it near impossible to remove

from the lines using the present cleaning

techniques.

A MICROSCOPIC VIEW OF ACTUAL

WALL SOIL IN A BEER LINE. THIS IS

THE BIOFILM CALLED BEERSTONE.

THE FORTRESS OF CALCIUM OXALA-

TE CRYSTALS THAT PROTECTS THE

MICRO ORGANISMS.

IMAGE BY PICKETT MAGNIFIED 600X

The different densities and colors of the soiled

material. In viewing these soil materials under

a microscope, it is all beerstone in different sta-

ges of formation. The white colored materials

are individual oxalate crystals. The browner

to dark brown color material is due to varying

degrees of beerstone formation. The size and

age of this beerstone determine the density

and color of the material as seen.

In the article “The Extraordinary World of

Biofilms”, it discusses “managed” frequent

cleaning, the article continues and indicates

because the lines cannot be completely cle-

aned by conventional methods due to biofilm.

This is tacit admission by two of the world re-

cognized brewing scientists, Quote: “That pre-

sent methods used to clean, alarmingly, never

fully remove the biofilms and consequently the

biofilms slowly regrow before once again scra-

ped on subsequent cleaning”. (3)

The article further says: Quote:“cooling the

beer in the serving line to 4 degrees (39.2°F)

would reduce the growth rate of microorganis-

ms by almost 10 fold.” It goes even further to

say: “the use of cold rooms in Ireland supports a

four week cleaning cycle”. (3)

The same article emphasizes “the efficacy of

the cleaning systems by monitoring microbi-

al counts in real time using ATP also requires

to be put into context (And rightly so). That

planktonic cells are only indicative of the pre-

sence of biofilm and alarmingly underestimate

the real loading attached to the surface.”

,

,

“That present methods used to cle-

an, alarmingly, never fully remove

the biofilms and consequently the

biofilms slowly regrow before once

again scraped on subsequent clea-

ning”. (3)

THE VARYING DEGREES OF

Beerstone Formation

MECHANICAL CHEMICAL

Quote: “Although repeated in pubs, bars

and clubs across the world, the reality is

that even weekly cleaning does not com-

pletely remove or kill the biofilm com-

munity. Accordingly, regrowth occurs

which requires to be ‘managed’ through

frequent line cleaning. Where the bio-

film is not managed there are two conse-

quences: (i) the biofilm becomes increa-

singly consolidated and progressively

harder to control through cleaning and

(ii) product quality is increasingly com-

promised such that clarity declines and

off-flavors become pronounced.” (3)

,

PRESENT IMPLICATIONS FOR

Beer Line Cleaning

Quote: “The realization that biofilms are the

way things are in the ‘real world’, has impli-

cations for our understanding of hygiene

in particular and microbiology in general.

Alarmingly though, it is increasingly argued

that despite effective and regular cleaning

regimes, biofilms are never fully removed

and consequently slowly regrow before being

once again scraped on subsequent cleaning.

This is also relevant where sanitizers and disin-

fectants are tested against typically free floa-

ting planktonic organisms whose physiology

is very different to the mixed community of

sessile cells protected in the matrix of a bio-

film.” (3)

This is the current situation and the primary

reason for an advanced cleaning system.

PRIMARY REASON FOR AN

AdvancedCleaning System

MECHANICAL CHEMICAL

The particulate matter or abiotic material

accumulates along with the yeast and other

organisms. The velocity is not high enough

to remove this material. Contrary to popular

belief, “hide in the cracks”, the micro organisms

attach to the line walls via pili, flagella,or

exacelluar polysaccharides. This is the main

method of attachment. By correct cleaning

methods all the soil precursors are removed

thereby extending the cleaning cycle time.

100% CLEAN LINES

Brewery Fresh Beer

WHAT DO WEHAVE TO

CLEAN?

SOIL IN A DRAFT BEER LINE WILL LAY

IN THE BOUNDRY LAYER OF THE LINE AND

FORM A FORTRESS OF BIOFILM CALLED BEERSTONE.

THE SCIENCE OF FLOW

The principle employed in the Tsunami is quite simple. Insert a small volume of gas in the line and it will expand to the wall eliminatingthe boundry layer. This will cause the liquid to form cylinders, The cylinders are pushed by the gas behind. This causes the liquid to moveperpendicular to the wall. This is what generatesthe scrubbing action. This will happen thousands of times in a cleaning cycle, try to scrub your hands several thousand times in a 15-20 minute cleaning cycle. You can be sure they will be clean.

LAMINAR FLOW - TURBULENT FLOW

SLOW FLOW

NORMAL FLOW

FASTEST FLOW

NORMAL FLOW

SLOW FLOWBOUNDRY LAYER NO FLOW ZONE

THE SCIENCE THAT MAKES

THE TSUNAMISUPERIOR.

ABOVE: FLOW IN A DRAFT BEER LINE

BOUNDRY LAYER NO FLOW ZONE

BUBBLES CREATE

THOUSANDS OF LIQUID

CYLINDERS THAT MOVE

PERPENDICULAR TO THE

WALL OF THE LINE WHILE

SCRUBBING AND REMOVING

ALL SOILS AND BEERSTONE

IN THE BOUNDRY LAYER.

A LAYER NOT CLEANED

BY CURRENT PUMPS.

The particulate matter or abiotic material

accumulates along with the yeast and other

organisms. The velocity is not high enough

to remove this material. Contrary to popular

belief, “hide in the cracks”, the micro organisms

attach to the line walls via pili, flagella,or

exacelluar polysaccharides. This is the main

method of attachment. By correct cleaning

methods all the soil precursors are removed

thereby extending the cleaning cycle time.

100% CLEAN LINES

Brewery Fresh Beer

WHAT DO WEHAVE TO

CLEAN?

SOIL IN A DRAFT BEER LINE WILL LAY

IN THE BOUNDRY LAYER OF THE LINE AND

FORM A FORTRESS OF BIOFILM CALLED BEERSTONE.

THE SCIENCE OF FLOW

The principle employed in the Tsunami is quite simple. Insert a small volume of gas in the line and it will expand to the wall eliminatingthe boundry layer. This will cause the liquid to form cylinders, The cylinders are pushed by the gas behind. This causes the liquid to moveperpendicular to the wall. This is what generatesthe scrubbing action. This will happen thousands of times in a cleaning cycle, try to scrub your hands several thousand times in a 15-20 minute cleaning cycle. You can be sure they will be clean.

LAMINAR FLOW - TURBULENT FLOW

SLOW FLOW

NORMAL FLOW

FASTEST FLOW

NORMAL FLOW

SLOW FLOWBOUNDRY LAYER NO FLOW ZONE

THE SCIENCE THAT MAKES

THE TSUNAMISUPERIOR.

ABOVE: FLOW IN A DRAFT BEER LINE

BOUNDRY LAYER NO FLOW ZONE

BUBBLES CREATE

THOUSANDS OF LIQUID

CYLINDERS THAT MOVE

PERPENDICULAR TO THE

WALL OF THE LINE WHILE

SCRUBBING AND REMOVING

ALL SOILS AND BEERSTONE

IN THE BOUNDRY LAYER.

A LAYER NOT CLEANED

BY CURRENT PUMPS.

For many years I have cleaned a long line system according to in-dustry standards. I could never understand the reasoning behind the two week cleaning cycle. Six years ago I committed to studing the flow of beer in a draft line. There were several things that I disco-vered that affect cleaning. The first and foremost was the length of the beer line and then the understanding of the soils and how they attached to the beer lines. Once coming to the conclusion that the individual soils are intertwined with each other and not as individual components, I understood the major problem in cleaning draft beer lines. In the last several years this conclusion was fortified by peo-ple I consider the foremost microbiologist and beer scientists in the world. The conclusion reached by each of us independently was that biofilm was a major issue in any food system. That biofilm exhibited characteristics not of the individual components but of a mixture of all exhibiting other characteristics other then what we knew and un-derstood. Saving the soils collected after cleaning and visually ob-serving them under a microscope, gave a whole new perspective. What I observed was beerstone. At that moment, It was understood that beerstone and biofilm are one in the same. It was then this became a formidable project to ensure that beerstone was com-pletely removed from the system. After initiating studies on flows in lines, it was discovered that liquids actually flow in layers. The layer that was specifically interesting to this problem was the boundry lay-er. This was the layer that did not move and protected the beerstone and other biofilms attached to the line walls from current cleaning methods. The result of these studies and observations was a paten-ted method to remove this laminar sublayer and allow the cleaning agents to attack the soil. The TSUNAMI provides the mechanical action (shearforce) necessary to remove the soil from the line walls. The intended result of this method was to decrease the amount and frequency of cleaning beer lines and providing the best quality beer to customers as the brewer intended.

All for the love of beer,

Conclusion

Conclusion

All for the Love of Beer.

www.tsunami.works

THIS CLEANING SYSTEM IS NOT JUST ANOTHER PUMP, NOT ANOTHER PASSIVE SYSTEM, THE TS-UNAMI LINE CLEANING SYSTEM IS THE COMPLETE LINE CLEANING SYSTEM SO UNIQUE THAT IT IS PA-TENTED. IT UTILIZES COMPLETE UNDERSTANDING OF THE COMPOSITION OF THE SOIL AND FLOW SCIENCE TO CLEAN LINES. IT SCRUBS. IT CLEANS LIKE NO OTHER PIECE OF EQUIPMENT.

Cleaning a tube or beer line is different than

cleaning flat wall. This method eliminates the

laminar sub-layer which allows scrubbing in

a cylinder to remove all soils attached to the

beer line walls. This is accomplished by forcing

the water to move perpendicular to the inte-

rior wall rather than as a parallel waving flow

(turbulent flow). Cleaning with the Tsunami

Line Cleaning System℠ generates a liquid she-

ar force unparalleled by any other method of

cleaning. It knows no bounds, whether the line

is restricted or choked down, whether the line

goes up or down. This method completely eli-

minates biofilm, beerstone (bio-stone), mine-

rals, micro-organisms or any other debris from

the entire system.

This horrendous shear force happens thous-

ands of times in a 15 minute cleaning cycle.

This is an unheard of amount of scrubbing.

For example, try to rub your hands that many

times when washing them. This is accomplis-

hed by separating the liquid into cylinders of

liquid which also carry out the soil. It is neces-

sary to have cleaning solutions formulated in

such a manner as to have the ability to penet-

rate but not too slippery as to diminish its abili-

ty to interfere with its wall shear ability.

Unfortunately, other methods do not eliminate

the biofilm and therefore they only slow down

or control the growth of organisms, hence cle-

aning every week to two weeks.

WHY ARE THE LINES REGULATED TO BE CLEANED EVERY 2 WEEKS ?

IF THE BEER IN A KEG IS GOOD FOR 60 DAYS,

QUESTION

MOST TIMES THE DRAFT LINE SYSTEM IS CONTAMINATED WITH BEERSTONE & OTHER BIOFILM.

ONLY THE TSUNAMI WITH MECHANICAL ACTION.

LEAVE IT 100% CLEAN. & MOVE TO A 4 WEEK CLEANING CYCLE.

ANSWER

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www.tsunami.works

MECHANICALNOT CHEMICAL

A MAJOR DEVELOPMENT IN DRAFT BEER LINE CLEANING

(1) Draught beer quality - challenges and opportunities(2) David Quain - Lines and Cleaning page 6(3) Stages of biofilm development- (from Stoodley et Annu Rev Microbiol 2002, 56,187 Brewer and Distillers International-July 2009-David Quain and Erna Storgards