Cleaning

Interior Vessel Cleaning

All CIP vessels are cleaned with a 5% caustic solution, heated to 80ºC and recirculated through the CIP ball for 30 minutes.

Cleaning Schedule

|Vessel| CIP Cleaning Period| Full dismantling | |-----|-------|------| |Boil Kettle | After every brew day | Every 3rd brew | |Mash Mixer | After every brew day | Every 3rd brew | |Lauter Tun | After every brew day | Every 3rd brew | |Heat Exchanger | After every brew day | Every 3rd brew | |HLT | Every 3 months, if necessary | Every 3 months, if necessary | |CLT | Every 3 months, if necessary | Every 3 months, if necessary | |CCVs | After every transfer | Every 3rd transfer | |BBTs | After every transfer | Every 3rd transfer | |Kegs | After every transfer | Every 3rd transfer | |Taps | N/A | Every week | | Brewery floor | | | | Chain-Vey | | | | Mill room | | | | Vessel exteriors | | |

Passivation Schedule

|Vessel| Period| |-----|-------|------| |Boil Kettle | Every 3 months | |Mash Mixer | Every 3 months | |Lauter Tun | Every 3 months | |HLT | Every 3 months | |CLT | Every 3 months | |CCVs |Every 3 months | |BBTs | Every 3 months | |Kegs | Every 3 months |

Cleaning Procedures

Brewhouse cleaning

Required Supplies: * Scoop * Weight scale * pH test strips * Portable pump * 2 1.5" hoses * 4 TC clamps and gaskets

Normal Cleaning

  1. Put 50L of 80ºC water into the vessel.
  2. Add 0.75-2.25kg of Brewguard Powdered Brewery Cleaner.
  3. Circulate for 30 minutes maintaining 80ºC.
  4. Transfer solution to next vessel.
  5. Rinse vessel with hot water until pH is neutral.

Sanitizing

  1. Add 50L of 80ºC water to vessel
  2. Add 150mL of Peracetic Acid to the water
  3. Circulate through spray ball for 20 minutes
  4. Verify that the pH of the acid is still 2.0 or less
  5. Discard acid solution. Do not rinse.

Beer Stone cleaning (acid first)

The following is adapted from Birko's description of the procedure at Breckenridge Brewery for cleaning the brewhouse equipment, in which acid is done before the cleaner, as it is more effective on the "baked-on" organic material from the higher temperatures in the brewhouse:

  1. Add 50L of water to boil kettle, begin heating to 60ºC
  2. Add 0.78-1.6L of Acid 14 to the water
  3. Circulate through spray ball
  4. When temperature reaches 60ºC, circulate for 25 more minutes
  5. Transfer acid solution to mash mixer
  6. Circulate through spray ball for 15-20 minutes
  7. Transfer acid solution to lauter tun
  8. Circulate through spray ball for 15-20 minutes
  9. Verify that the pH of the acid is still 2.0 or less
  10. Discard acid solution. Do not rinse.
  11. Put another 50L of water into the boil kettle and heat to 60ºC
  12. Add 0.75-2.25kg of Brewguard Powdered Brewery Cleaner to water, raise heat to 80ºC
  13. Circulate for 45 minutes maintaining 80ºC
  14. Transfer solution to mash mixer
  15. Add 2.3kg more of Bru-R-Ez®
  16. Circulate for 30 minutes
  17. Transfer solution to lauter tun
  18. Add 2.3kg more of Bru-R-Ez®
  19. Circulate for 30 minutes
  20. Discard solution
  21. Rinse boil kettle, mash mixer and lauter tun with hot water until the pH of the water and walls of vessels is neutral (~7)

Hot and Cold Liquor Tanks

These only contain water, so should not require cleaning, in general. However, over time calcium deposits from water can form on the insides of the tanks and in the piping. These should be checked every 3 months when empty and, if there is any dirt or build-up, the tanks are to be cleaned via CIP as the other tanks are cleaned.

Unitanks and BBTs

  1. Rinse with water
  2. Non-caustic cleaner
  3. Rinse
  4. Acid
  5. Rinse
  6. Sanitizer

Another advantage of non-caustic cleaner is that it can be used wth CO2 without being degraded or risking a vacuum (which can cause a tank implosion). This avoids having to purge the CO2 of out them, cleaning and then filling with CO2 again, saving time and money.

Heat-Exchanger

TODO: write this

See the [manual][manual-heatexchanger].

Kegs

TODO: summarize keg washer manual instructions here

See [the Operations Manual][manual-kegwasher] for more information.

Taps

The taps are cleaned every week by removing them and soaking them in PBW overnight. After rinsing, they can be put back on. The hoses are also all replaced every week, at a minimum.

The shanks are cleaned in-place with a brush and an alkaline cleaning solution and the cleaner is removed by scrubbing with a clean water-soaked brush.

The keg couplers are also cleaned every week by disassembling them and soaking them in an alkaline cleaner.

The CO2 hoses are inspected every week to make sure there is no beer in the lines. If there is, they are replaced.

Brewery floor & drains

Our floor is coated in a urethane undercoat covered by an epoxy top coat. The flooring is not just concrete because the high temperatures, sticky wort and caustic cleaners that will be used on the floor would readily eat away at the concrete alone. We need to take good care of the coating on the floor so it lasts a long time -- any chips or holes made in the coating will allow water and caustics to seep under the floor and cause it to fail. If you see any problems with the floor, bring it to attention.

We also keep our floor looking nice, because dirty floors can lead to infected product. Mold growing on the floor can make its way into the beer, and it certainly tells our customers we don't care about our factory. We want people to leave talking about how beautiful even our floor is! ;)

The brewery floor should be cleaned every _ with a spray down of a PH neutral cleaner (e.g. simple green or ZEP) at a high dilution (___) and a good brushing with a soft brush. It is important not to ignore the hard to reach places like under piping. The cleaner should be rinsed with a good wash of water.

Chain-Vey

Because grain is mostly dry and has no oils, the Chain-Vey should stay fairly clean and, if the base malt grain is always sent through it last, should only have the palest of grain dust in it. However, it should be cleaned every 3 months by putting "cleaning balls" through it that act as brushes to clean the inside of the pipe, the chain and discs.

TODO: get these cleaning balls and write instructions for using them.

Mill Room

The mill room should remain free of grain dust. However, no system is perfect and grain dust particles are very small, so they may escape. The mill room must be checked after every use of the mill (after the mill is turned off!) for dust. If there is dust, contact Troy and we will find a way to prevent it in the future.

Any dust or spilled grain should be cleaned up immediately and thrown away (do not put it in the mill hopper).

Passivation

All the stainless vessels are to be passivated every 3 months. Before passivating, they must be clean. See above. The recommended procedure is to use a 50% Nitric and 50% Phosphoric acid blend.

TODO: citric acid is safer than Nitric/Phosphoric, so we should use that instead.

Procedure:

  1. Clean tanks (see above)
  2. Put 50L of 80ºC water in vessel
  3. Add 0.8-1.6L of Acid 14
  4. Circulate through CIP spray ball for 30 minutes with pump
  5. Rinse with 80ºC water until the pH of the rinse water is neutral (~7)
  6. Leave overnight to air dry

Maintenance

Brewery Pumps

TODO: write this

Air compressor

TODO: write this

See [the manual][manual-IngersollRand-2475] for more information.

Chain-Vey

TODO: write this

See [the manual][manual-chainvey] for more information.

Lubrication

The Drive Unit gear motors must be lubricated every 2 years or 10,000 hours of usage (which would be 24x7 use for 13 months, which is much more than we'll use it). The correct oil is Klüberoil 4UH1-460N. See the Chain-Vey manual for instructions.

Boiler

TODO: write this

Mill

TODO: write this

See [the manual][manual-Engl-mill] for more information.

Walkie-stacker

To make sure that the walkie-stacker is being taken care of and is safe to use, the daily checklist form should be filled-out every day. It's a bit pedantic, but should be quick and easy to do once it's been done a few times. If the walkie-stacker breaks down, people have to lift heavy things without it, which is much harder than filling out this checklist every day.

The forms and documentation from the manufacturer are here:

Cold room refrigeration

TODO: write this

Exterior Vessel Cleaning

The stainless brewhouse and tanks look great when shiny and they are very visible to our customers. We will keep them shiny and clean.

Procedure

  1. Mix a mild detergent with water in a 5-gallon bucket
  2. Use a soft scrub brush on a long handle to wash the outside of the tanks from the ground. Brush in the direction of the grain in the metal.
  3. Take the bucket to the brewhouse deck and wash the tops of those tanks
  4. Take the bucket to the mezzanine and cat walk and wash the tops of the tanks
  5. From the mezzanine and catwalk, rinse the tanks with a hose and hot water, with careful attention to rinse soap away from manways and ports. Avoid spraying outside the brewery area to keep the water on the brewery floor.

Checklists

| Checklist | Frequency | |-----------|-----------| |Brewery End-of-Day| Daily | Serving cold room | | | Cellar cold room | | | Keg-washer | | | Air-compressor | | | Chain-Vey | Weekly | | Walkie-Stacker | Daily | | CO2 bulk tank | |

Cold rooms

This checklist should be verified weekly:

  • Door stays open on its own, i.e., it does not close automatically
  • Respirator is in the room within arm's reach of the door
  • CO2 alarms are operating properly

Keg-washer

  • Check valves for moisture

Air compressor

  • Oil level

Chain-vey

| Part | Checks | |-------|-------|---------| | Drive Unit | All fastening hardware is tight, sprocket teeth for wear, gearbox oil level, clean the fins, remove any product buildup/dirt | | Turnaround Unit | Chain tension, hardware is tightly fastened, sprocket teeth, excessive wear, clean product buildup/dirt | | Discharge Valve | Alignment, open/close functioning, clean product buildup/dirt | | Pipe | Hardware is tightly fastened, dents or other damage, clean product buildup/dirt | | Chain and discs | Inspect for wear and damage, confirm that the connector link is present and tightly fastened | | Sight Glass | Check for discoloration or dirt, scratches, cracks and other damange. | | Inlets | Clean product buildup/dirt |

See the Chain-Vey Manual for details and troubleshooting.

Cold room refrigeration

TODO: write this

CO2 bulk tank

TODO: write this