How to Grow your own lab. Tom Shellhammer

How to Grow your own lab Tom Shellhammer What is ASBC about? Community Science Quality Volunteerism Key Contributions coming from ASBC Community ...
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How to Grow your own lab Tom Shellhammer

What is ASBC about? Community Science Quality Volunteerism

Key Contributions coming from ASBC Community  Annual Meetings + Webinars  Opportunities to connect with colleagues and build a network  Access to information, support, and colleagues for problem-solving, quality assurance, safety, and improved performance Science  Brewing and Scientific Publications  Journal of the ASBC Quality  ASBC Methods of Analysis (MOA)  ASBC Technical Committees  Check Sample Program  Calibration Standards (Hops and Soluble Starch)  Scientific Tools (Crimp Bars, Malt Sieves, etc.)

Expanded Member Benefits since 2014 ASBC Methods of Analysis (MOA) – free • Includes more than 200 methods, evaluated and authorized by ASBC based on industry-wide collaborative studies • Beer Flavor (624) and Hop Flavor (594) Databases also included

Fishbone References - free • An essential online troubleshooting and diagnostic tool which includes fishbones covering 33 critical process and product topics • Identify and solve issues in any sized brewery operation

Webinars - free • Sensory series (2014) • How to grow your lab series (2015)

Resources for the emerging and craft brewer • ASBC Craft Brew Subcommittee • Webinars – Sensory – Microbiology – Chemistry

Grow your own lab • ASBC offers many resources for building a lab – “A Guideline for Growing your Quality Laboratory” • Recommended instruments and testing regimens • Organized by production volumes (bbls/year) • http://methods.asbcnet.org/eXtras/Growing_your_lab.pdf

– Methods of Analysis • Internationally standardized testing protocols

– Network of industry professionals

An Introduction to General Brewing Lab Setup Presented By: Eric Jorgenson Highland Brewing Co.

Where to Start?  QA/QC Architecture    

Biological Chemical Physical Sensory  (ASBC sensory webinar series!)

 Analysis & communication  CBSC Guide to Growing Your Quality Lab  http://methods.asbcnet.org/eXtras/Growing_your_lab.pdf

Where to Start?

Where to Start?

~$1K ~$2–15k ~$200

~$30 ~$10K ~$300 ~$4-8K

What to Consider When Purchasing Instrumentation

 What level of training/skill is required to run the analysis?  What is the total cost of ownership (instrument vials, calibration equipment, maintenance, etc.)?  Does it need to be run in a laboratory (in-line or at-line)?  What type of waste will be generated?  Can more than 1 method be run by the instrument?

Outsourcing  What can your suppliers provide (water, malt, hops, cleaning chemicals, etc.)  How fast do you need the result (do you want to be able to act in real time?)  Cost in-house versus cost for outsourcing (include shipping!)

Sampling Plan • What level of risk are you willing to accept? • What level of redundancy is built into your system – (pasteurizer, sampling throughout process)?

• Guidelines are available: • Included in ASBC Methods of Analysis for each test.

Example: Sampling Plan Overview from Highland Brewing •

Raw material



– Water • •

– – – – –

Cl, Fe, Mg, Ca, Alkalinity Micro

– Grain – sensory • •

supplier provides analytics Grist analysis (mill drift)

– Hops – sensory •

supplier provides analytics



Brewhouse – – – –



pH, EA Pitching CC, viability Wort stability micro Wort DO – need high-level sensor

Cellar – – – –

pH, EA, VDK (taste & distillation) Micro (fermentation, crash) ATP CIP verification Pre-filtration TTT sensory panel



ATP CIP verification DO, CO2, NTU ABV, EA, color, pH Post-filtration TTT sensory panel Micro

Packaging – – – – – –

– CO2 purity @ delivery – not tested – Yeast – micro, CC, viability



Bright

ATP CIP verification DO, CO2 ABV, EA, color, pH Fill height Bottled TTT sensory panel Micro

Archive – Keep 12 bottles/run, re-test as needed

Example: Sampling Plan from Highland Brewing • Raw material – Water • Cl, Fe, Mg, Ca, Alkalinity • Micro

– Grain – sensory • supplier provides analytics – FAN (Free Amino Nitrogen), protein, friability, color, moisture, viscosity, kernel size, etc.

• Grist analysis (mill drift)

– Hops – sensory • supplier provides analytics – alpha acids, beta acids

– CO2 purity at delivery – still acquiring hardware – Yeast – micro, cell count, viability

Example: Sampling Plan from Highland Brewing • Brewhouse (taken by brewers in the brewhouse) – – – –

pH, Original Gravity Pitching Cell Count, viability Wort stability micro Wort DO (dissolved oxygen) – need high-level sensor

• Cellar (analyzed in the lab) – – – –

pH, gravity, ‘organoleptic’ diacetyl, VDK distillation Micro (high krausen, crash cool) ATP swab CIP verification Pre-filtration True-To-Type sensory panel

Example: Sampling Plan • Bright Beer Tank – – – – –

ATP swab CIP verification Dissolved oxygen, dissolved CO2, Turbidity ABV, gravity, color, pH Post-filtration True-To-Type sensory panel Micro

• Packaging – – – – – – –

ATP swab CIP verification Dissolved oxygen, dissolved CO2 ABV, gravity, color, pH Fill height Cap crimp Bottle True-To-Type sensory panel Micro

• Archive – Keep 12 bottles/run, re-test as needed

Example: Data Analysis at Highland Brewing • Start with the end in mind. Gaelic Ale Color

120.0

35

100.0

30 25

80.0 SRM

Dissolved Oxygen (ppb)

Bright Tank DO levels by process

60.0 40.0

20 15 10

20.0

5

0.0 4/21

6/10

7/30

9/18

11/7

12/27

0 5/31/14

2/15

Histogram - Fermenter Micro

9/8/14

10/28/14

12/17/14

Free Chlorine

100

2.00

Free CL (ppm)

90 80

Percent

7/20/14

70 60 50 40

1.50 1.00

20 10 0

Severity of contamination

Free Cl HL Free Cl City

0.50 0.00

30

Free Cl CL

Phases of Control Charting • Phase I – Setting up control limits – Start with process you believe is in control – Sample, Model (calculate CLs), Graph • Phase II – Monitor process

Phase I – Control Charting

x z

Control Chart of Stable Process

X-Bar Chart

101.50 101.00 100.50 100.00 99.50 99.00 98.50 98.00 97.50 97.00 1

4

7

10

13

16

19

22

25

28

Sensitizing Rules 4 of 5 points beyond 1σ 6 points increasing (decreasing) Run of 8 on one side of the center line 2 of 3 points outside 2σ but still within control limits • 14 points alternating up and down. • • • •

Control Chart – Sensitizing Rules X-Bar Chart

102.000 101.500 101.000 100.500 100.000 99.500 99.000 98.500 98.000 97.500 97.000 1

4

7

10

13

16

19

22

25

28

Lab Design • • • • • • • • • •

New space or existing space What will be located in the lab? micro, chemistry, sensory? Hoods – chemical and microbiological Solvent, acid, base, and waste storage Safety eyewash stations HVAC – Most labs need to be kept at stable temperatures Electrical – Dedicated circuits Autoclave Sample preparation space Plumbing – dishwashers, sinks, ultrapure water

Training & Validation • Take the time to write work instructions and/or standard operating procedures. – Need consistency

• Use PPE – gloves, goggles, lab coats • Locate all training documents in a centralized location (only 1 version of the truth). Assign a person to maintain the documents. • Put checklists in place to ensure thorough training and that training is conducted the same way between all operators. • Use external and internal controls • May choose to participate in validation programs – ASBC Check Sample Program

Additional Resources • Siebel Institute of Technology • OSU – PACE (Professional and Continuing Ed) https://pace.oregonstate.edu/beer

Additional Resources • ASBC members – Craw Brewers Subcommittee

• ASBC Check Sample service • ASBC Fishbone Diagrams

World Brewing Congress Denver, CO, Aug 13 – 17, 2016

Questions