Category Archives: Auditing

Graeme Hall B.Sc., Dip. Brew., D.M.S. – Consultancy Corner

We’ve another excellent consultant to introduce to you; Graeme Hall B.Sc., Dip. Brew., D.M.S. of GRH Consultancy, who has taken the time to discuss his extensive experience in the industry for us below.

www.grhconsultancy.co.uk

I have been in the Brewing Industry for over 30 years, and have worked for 4 different breweries and have spent the last 20 years at Frederic Robinsons as Operations and Packaging Manager. So, I have vast knowledge of the requirements to run a Quality Brewing or Packaging operation.

In early 2016 I decided to set up my own Consultancy to help other operations improve their businesses through Continuous Improvement. Something to which I bring the experience of successfully having been through and passed numerous BRC, SALSA, Tesco and M&S audits with my time at Robinsons.

At Robinsons I was responsible for the processing (cold conditioning, stabilising and filtration) and either Bottling, Cask Racking or Kegging (including Petainers) of over 400 products from approximately 60 breweries. In my time there, I was involved in, and latterly lead, the project teams that replaced every piece on bottling equipment in the Bottling Hall, installed and commissioned 19 tanks with SCADA control, installed an in line Cask Washer and 5 head Racker. I purchased a Keg Washer, labeller and keg seal applicators as well as the Petainer filler. This has provided me with invaluable experience I now apply to my consultancy work.

I received a Distinction in my HACCP Level 3 assessment in 2016 and I Passed the IOSH Managing Safety course in 2015​. In 2013 I was fortunate enough to become Chairman of the Institute of Brewing and Distilling (IBD) – Great Northern Section. I am a Judge on the SIBA Beer Ex Finals Panel​. In 2017 I became a lecturer at Brew School in Bakewell and was invited onto the IBD Board of Examiners for the Packaging Diploma. I also became an auditor for SIBA for the FSQ audit. My experience is considerable and my commitment to the industry total.

The services I offer include preparing a bespoke HACCP plan for your brewery or packaging operation that if continued correctly will be acceptable not only as a legal requirement to produce safe beer or cider but also to go some way to be accredited to SIBA FSQ, SALSA and BRC.

The HACCP plan will include bespoke Flow Diagram, Hazard Analysis, Risk Assessment, Standard Operating Procedures for CCPs, Training matrix and CCP control documentation.

A basic training of HACCP for your bespoke operation will then be given to the team members.

Learn more at my website www.grhconsultancy.co.uk

or follow me on Twitter @GRHConsultancy

Our Returnable Drum Service

We here at Murphy and Son are committed to operating a strict environmental policy to help reduce our carbon footprint. As part of this, we operate a returnable drum service. 

Alongside helping protect our planet, our returnable drum policy allows you to avoid the time consuming and often expensive process of disposing of drums and IBCs personally. We are always happy to collect your empty Murphy & Son drums and IBCs from your site, simply agree a date and time with our team by calling sales on 0115 978 5494.

To cover the cost of supplying and transporting our containers throughout the UK and to allow for damaged containers and the process of laundering, label removal, cap replacement and micro swabbing, we do charge a small fee per container. The majority of this fee is credited back to you upon receipt of your returned containers.

A full break down of any and all costs of this service can be found below.

Container size and type
Charge per container
Refundable amount per returned container
Non-refundable carriage charge per container
25 litre drum £5.83 £4.73 £1.10
200 litre drum £20.70 £18.39 £2.31
600 litre IBC £111.42 £105.08 £6.34
1000 litre IBC £201.63 £183.90 £17.73

There are also a few other conditions of service we’d like to tell you about.

  • All containers must be returned in a rinsed, clean and sound condition.
  • To comply with Food Standards, we ask that nothing except the product we supply is stored in said container. Contaminated containers will be refused return and/or refund.
  • We only except returns within 12 months of purchase.
  • Please stack any empty containers on a pallet and wrap ready for transportation
    We’re happy to provide a roll of shrink wrap for this purpose, just give us a buzz to request.
  • We only accept containers supplied by Murphy & Son Ltd, other suppliers’ containers cannot be accepted.
  • This service is only available on the UK mainland

If any of the above conditions aren’t met, then we reserve the right to refuse refund.

Packing your drums ready for collection…

25 litre containers Palletise in a 4×4 layout, minimum of 2×16-32 units and no more than 4 drums high, a total of 64 units
200 litre containers Palletise a minimum of 2 containers with a maximum of 2×4 per pallet, a total of 8 units
If the number of containers you use is very small, we will accept a pallet with less items if this is pre-agreed and within the required 12 month return time.

We’re committed to ensuring the quality and efficiency of this service, therefore if you have any questions please don’t hesitate to get in touch via info@murphyandson.co.uk or by calling our Sales Team on 0115 978 5494.

Thank you from all the Murphy & Son team, for your continued custom and helping us do our bit for the environment.

Happy brewing!

Water, Water Everywhere. Murphy and Son Ltd

Water, Water Everywhere

We take treating your liquor very seriously at Murphy’s. If you purchase any of our liquor treatments please remember you are entitled to a free liquor analysis and our technical support. We will recommend the most suitable treatment for your brewery.
Send in 50ml of your water to our Laboratory

Send in 50ml of your water to our Laboratory

Introduction

Beer contains approximately 90% water, and the importance of the liquor to final beer quality cannot be over-estimated. Historically a correlation was observed between the liquor composition of an area and the type of beer that the region could best brew. The Pale Ales of Burton-on-Trent and Edinburgh, Porters of London, Stouts of Dublin and Lagers of Pilsen are classic examples. Water falling as rain, hail, sleet or snow is pure, but dissolves gasses such as oxygen and carbon dioxide from the atmosphere. On reaching the ground the water runs off into rivers, streams and lakes and on in some cases to reservoirs. The composition of the water in the reservoirs is dependent upon the nature of the catchment area. In areas where the rocks are hard, the water will not penetrate deeply, and will be ‘soft’ – that is low in dissolved salts. In areas where the rocks are more permeable – gypsum obrewing liquorr limestone for example – water will penetrate readily and dissolve many minerals on its way to the reservoirs to become ‘hard’.

The water supplied by local Water Authorities is required to be potable – that is fit to drink and free from pathogenic organisms. In order to reduce microbiological counts chlorine will usually be added, but the water is not sterile. Fortunately however the micro organisms found in water are not beer spoilage organisms, being unable to survive the conditions of high ethanol and hop resin levels and low pH found in beers. So the objective of liquor treatment is to convert the water sent to us by the Water Authorities into acceptable brewing liquor. This we achieve by the removal of unwanted ions and addition of required levels of desirable ions

DWB Liquor Treatment from Murphy's

DWB Liquor Treatment from Murphy’s

Calcium

Of the ions required for brewing, calcium is by far the most important. This is because of the acidifying effect that calcium has on the wort.

Wort contains large amounts of phosphates derived from the malt, and these have a buffering effect – that is they tend to mop up hydrogen ions and keep the pH higher than desired. Calcium ions precipitate phosphates as insoluble calcium phosphate and release hydrogen ions into the wort. It is worth mentioning at this point that whilst the pH of the wort is critical, that of the water in the HLT is not. The pH of water may vary from about pH 5 to pH 8 dependent upon the levels of dissolved carbon dioxide – even de-ionised water can have pH levels as low as 5 after exposure to the air. However the carbon dioxide is driven off by heat in the HLT and the pH of the water will rise.

A combination of the presence of calcium ions and the decrease in pH has a number of effects on the brewing process:

The lower pH improves enzyme activity and thus wort fermentability and extract.

The optimum pH for ß-amylase activity is about 4·7. Wort produced from liquor containing no calcium has a pH in the order of 5·8 – 6·0, compared to values in the range of 5·3 – 5·5 for worts produced from treated brewing liquor. The activity of the ß-amylase then is greatly enhanced by the addition of calcium, this exo enzyme increasing the production of maltose from Amylose, and thus making worts more fermentable.

Calcium has an almost ‘chicken and egg’ effect in the precipitation of wort proteins, both during mashing and during the boil.

Protein-H + Ca2+ Protein-Ca + 2H+

The hydrogen ions released further reduce the pH which encourages further precipitation of proteins. Proteins are also degraded, that is converted to simpler substances by proteolytic enzymes called proteases. These are found in the malt, and have optimum activity at pH values of about 4·5 – 5·0. The reduction in pH then caused by the presence of calcium encourages proteolysis, further reducing protein levels and increasing wort Free Amino Nitrogen levels (FAN). FAN compounds are utilised by the yeast during fermentation for the manufacture of Amino acids, and an increase in FAN levels in the wort improves the health and vigour of the yeast. High protein levels in beers also have negative effects, making beer more difficult to fine and encouraging formation of hazes, in particular chill hazes. Product shelf life can also be adversely affected.

Calcium ions protect the enzyme a-amylase from inhibition by heat.

a-amylase is an endo enzyme, cleaving the internal 1,4 glucosidic links of amylopectin resulting in a rapid reduction in wort viscosity.

It can be seen then that the presence of calcium has positive effects on the activity of both a-amylase and ß-amylase, two of the most important enzymes in the brewing process.

The drop in pH encouraged by Calcium ions in the mash and copper helps afford the wort and subsequent beer produced a greater resistance to microbiological infection.

The reduced pH of the sparge liquor reduces extraction of undesirable silicates, tannins and polyphenols from the mash bed.

The extraction of such materials is encouraged by alkaline sparge liquor. These materials are very undesirable, contributing to harsh flavours, hazes in the finished beer and decreased beer stability.

Calcium precipitates oxalates as insoluble calcium oxalate.

This again occurs in both the mash tun and the copper. Oxalates cause hazes in finished beers and also contribute to the formation of beerstone in FV’s, CT’s and casks. Oxalates are also thought to promote gushing in certain beers, although this is not generally a problem to the micro brewer.

The presence of calcium reduces colour formation in the copper.

This is due to the reduction of extraction of colour forming compounds such as anthocyanogens and pro-anthocyanidins during the sparge. The reaction: Reducing Sugar + Heat Melanoidins is also inhibited.

Calcium ions improve beer fining performance.

Calcium ions encourage yeast flocculation – being a divalent Cation it has a natural affinity for negatively charged yeast cells.
With all the above advantages of the presence of calcium and reduction in pH there is one minor disadvantage.

The reduction in pH causes a decrease in hop utilisation, giving less bitter beers.

This increases hopping costs, since more hops will be required to achieve a desired level of bitterness. However the optimum pH for hop isomerisation as used in the commercial production of isomerised hop extracts is about pH 10, so a reduction from pH 5·8 in a mash with untreated liquor to pH 5·1 out of copper for a treated brew is not too critical.

You will see that much of the calcium added to the mash is lost – precipitated out as phosphate, proteinate or oxalate. Since calcium is specifically required in the copper for further precipitation of these materials it is common to add calcium to the grist or Hot Liquor Tank and to then make a second addition to the copper. Where this is not practical it is quite acceptable to make a larger addition to the grist or to the H.L.T.

Bicarbonate

This ion needs to be very closely controlled in order to achieve good beer. High levels of bicarbonate cause high pH values throughout the brewing process according to the equation:

It should be noted that bicarbonate ions are rather more effective at raising wort pH than calcium ions are at reducing it.
The conversion of bicarbonate to carbonic acid is reversible until heat is applied, which drives off the carbon dioxide. This effectively removes the acidic hydrogen ion from the system by using it to form a stable water molecule. The wort pH therefore remains high and all the advantages derived from the presence of adequate calcium levels and reduced pH are lost.

We therefore see the following:

  • Harsh after-tastes in the finished beer
  • Extract will be reduced due to lower ß-amylase activity
  • Reduced protein precipitation due to high pH
  • Worts and beer more prone to infection
  • Increased extract of undesirable materials in the sparge, notably silicates, polyphenols and tanning

The net result of this is then to decrease beer stability and shelf life and to increase the likelihood of troublesome hazes. Colour will be darker, and flavour will be detrimentally affected. Hop utilisation will be increased, giving more bitter beers. It is then essential to ensure removal of excess bicarbonate. You will recall from Figure 1 that a hard water may contain 250 mgs/l of bicarbonate. The maximum level that can be tolerated without adverse effect for the production of pale ales is 50 mgs/l, and the preferred level would be about 25 mgs/l. It should also be noted that whilst additions of calcium may be made to HLT, grist and copper, the removal of bicarbonate must be achieved in the Hot Liquor Tank.

This may be done in a number of ways:

Deionsiation: Very effective, but high capital and revenue costs.

Lime treatment: Addition of carefully controlled amounts of lime (calcium hydroxide) to the HLT will precipitate the bicarbonate as calcium carbonate.

There are 2 major drawbacks:

  1. The amount added needs to be exactly calculated and over addition may result in an overall increase in alkalinity.
  2. The precipitated calcium carbonate can form a sludge on the bottom of the HLT that will need periodic cleaning.

Boiling: This again is a traditional method of removal of bicarbonate (Temporary Hardness) but again has 2 drawbacks:

  1. Very expensive.
  2. Only effective where the alkalinity is present as bicarbonate. If the levels of sodium, potassium or magnesium carbonates or hydroxides present are significant boiling will not be effective.

Acid Treatment: Now the most widely used method, for a number of reasons:

  1. Relatively inexpensive.
  2. Easy to use and does not produce sludge in the HLT
  3. May add desirable anions – sulphate or chloride.
  4. Can use phosphoric or lactic acids if no anions are wanted – eg for lager beers.
AMS Murphy and Son Liquor Treatment

AMS Murphy and Son Liquor Treatment

It is essential to rouse the liquor when acid treating in order to encourage the removal of the carbon dioxide. This can have corrosive effects on the materials of construction of HLT’s if left in solution.

Magnesium:

Is an essential element of brewing liquor because it is required by yeast as a co-factor for the production of certain enzymes required for the fermentation process. It is invariable formulated into liquor treatments at relatively low levels.

However caution must be exercised for 3 reasons:

  1. Excess magnesium can interfere with the reactions of calcium because its phosphates are more soluble
  2. Above about 20 mgs/l magnesium can give beer a sour and bitter taste
  3. In excess magnesium has a laxative effect

Sodium:

Is present in all beers. Excessive levels are undesirable as it imparts a sour and salty taste at high concentrations. The flavour is more acceptable when the sodium is present as chloride than as sulphate.

Potassium:

Is, like magnesium, a yeast co-factor and is required at trace levels for satisfactory fermentations. It is more acceptable than sodium from a flavour point of view, giving a salty taste without the sour notes. It is also gaining some favour as Doctors warn of the effects of high sodium intake on blood pressure. However potassium salts are very much more expensive than the sodium equivalents, and in excess potassium has laxative effects on the beer.

Sulphate and Chloride:

It is convenient to discuss the effect of these two ions together. Much is made in brewing literature of the impact of these ions on beer flavour characteristics – sulphate gives beer a drier, more bitter flavour, whilst chloride imparts palate fullness and to an extent sweetness. However what must be noted is that it is the ratio of the concentrations of these two ions that is significant, rather than simply the actual concentrations. A ratio of about 2:1 sulphate to chloride is about right for a bitter beer, and it makes little difference if the actual values are 500:250 or 350:175 mgs/l. As will be seen in Figure 3 ratios of 1:2 sulphate:chloride are recommended for mild ales, whilst a ratio of 1:3 may give best results for stouts or porters.

Sulphate and Chloride: It is convenient to discuss the effect of these two ions together. Much is made in brewing literature of the impact of these ions on beer flavour characteristics – sulphate gives beer a drier, more bitter flavour, whilst chloride imparts palate fullness and to an extent sweetness. However what must be noted is that it is the ratio of the concentrations of these two ions that is significant, rather than simply the actual concentrations. A ratio of about 2:1 sulphate to chloride is about right for a bitter beer, and it makes little difference if the actual values are 500:250 or 350:175 mgs/l. As will be seen in Figure 3 ratios of 1:2 sulphate:chloride are recommended for mild ales, whilst a ratio of 1:3 may give best results for stouts or porters.

Sulphur is essential for the fermentation process, since the yeast needs to manufacture the two sulphur containing amino acids, cysteine and methionine. Some yeast strains will use sulphur from sulphate ions for this purpose and will then excrete any excess as sulphite ions. These can then be reduced to form hydrogen sulphide or sulphur dioxide. Both of these materials have characteristic pungent odours and even at low levels can give unacceptable sulphury noses to the beer. Bacteria also have the ability to produce a wide variety of sulphury off flavours, including rubber, garlic and cooked vegetable.

Nitrate:

Levels of Nitrate are beginning to drop generally due to greater control of the use of nitrogenous fertilisers. Nitrates themselves are not a problem at levels below 50 mgs/l, however they can be reduced by yeast or bacteria to form Nitrites. These ions can then react with wort amines to form Nitrosamines, which are carcinogenic.

Trace Ions:

Metals such as Iron, Manganese, Copper and Zinc may be found in small quantities in water and are all utilised by yeast at levels below 1 ppm. Higher levels can cause colloidal hazes and metallic off flavours, particularly with higher levels of Iron. Silica should also be at very low levels in brewing liquor because of the likelihood of colloidal hazes being formed. Ammonia should be absent in brewing liquors, being indicative of contamination by sewage. Fluorine, present in most waters at about 1 ppm for dental purposes, has no detectable effect on the brewing process. However Chlorine, used for sterilisation, may be at relatively high levels at certain times of the year. This can cause problems since chlorine is a very reactive chemical and will readily react with organics to form chlorophenols. These have a medicinal (T.C.P.) flavour which is in some cases detectable at levels below 1 ppb. Chlorine will be lost to some degree by the heat in the Hot Liquor Tank, but not all water used within the brewery is from that source. Some brewers may use untreated liquor to break down to gravity in fermenter, and rinsing following caustic or acid cleaning cycles will typically be with untreated mains liquor. One solution is to treat both Hot and Cold Liquor Tanks with 10 ppm of Salicon Liquid 169 (20 mls in 10 brls liquor) and rouse vigorously to remove the chlorine. The sulphur dioxide reacts with chlorine in the manner described below – reducing reactive, undesirable and potentially harmful chlorine ions to chlorides.



Typical Liquor Analyses for Beer Types:
Bitter Mild Porter Lager
Calcium 170 100 100 50
Magnesium 15 10 10 2
Bicarbonate 25 50 100 25
Chloride 200 200 300 10
Sulphate 400 150 100 10

Nitrate – As low as possible
Metals – Zn, Cu, Fe,Mn Less than 1 ppm All figures are in ppm (mgs/ltr)

ams200

AMS Liquor Treatment

Please take a look at Murphy’s Liquor treatment range.

 

Murphy & Son’s 2017 On Site Training Day Dates 2017

Why not take part in one of our training days either at your own site or at our historic Prince of Wales Brewery Site in Nottingham?

You will be able to discuss the brewing process with one of our master brewers. Either learning for the first time or retraining in one or more of our specific categories.

All courses cost £85 + vat and include food and drink. Each delegate is given a USB containing the presentations to take home on the day.

All courses here at Nottingham start around 9.30am and finish around 4.30pm.

Available dates are shown below, please book as soon as possible to avoid disappointment.

If travelling is an issue, you can arrange a training day at your own brewery or at a local location. We can help you create a bespoke course for you. We will charge you our daily consultancy rate plus travel expenses and you can have as many delegates as you wish. We can even arrange for other brewers in your  area to attend, who will pay you for the course.

Please contact Frances Maud on Frances.maud@murphyandson.co.uk for more details or to make a booking.

LABORATORY DAY 2017

  • Thursday 27th April
  • Thursday 24th AugustCANCELLED!

Introducing you to basic science to produce beer with consistent quality. This course will cover the malting process, the mash, enzymes, pH buffering, the boil, protein coagulation, colour increase and flavour changes. You will be advised what equipment can be used to monitor pH’s, colour and bitterness and haze and there will be a demonstration on how to perform an optimisation and much more.

training-day-2

QUALITY ASSURANCE AND QUALITY CONTROL AWARENESS 2017

  • Thursday 25th May
  • Thursday 28th September

A training day that runs through the “world” of QA and QC. Aim is to arm the brewer ready for their initial foray with the subject. The course will cover: process monitoring and the process, microbiology, record keeping and quality systems i.e what does SALSA and HACCP want and what is it?

kettle-fining-addition

adding-isinglass

 

(PAST) BEER CLARITY 2017

  • Thursday 16th February
  • Thursday 29th June

adam-finingkettle-optimisations

This course will cover liquor composition and effect on stability, Brewhouse control, carrageenan, isinglass and auxiliary finings and cask preparation. The day ends with a very constructed troubleshooting session which leads to question and answers.

(PAST) YEAST MANAGEMENT 2017

  • Thursday 30th March
  • Thursday 13th July

This will cover the general overview of yeast, the fermentation process, handling live yeast, microbiology and cleaning and basic CIP.

trioSafeDepositNCYC

Please contact emily.kerrison@murphyandson.co.uk for more details or to make a booking.

SystemSURE II – ATP Hygiene Monitoring System. Rapid and Simple Solutions for Hygiene Testing

The SystemSURE II ATP luminometer is the next generation of luminometers. Designed with state-of-the-art electronics, this palm-sized system is easy to use, extremely sensitive and affordable.

Please contact our sales line, this device could be yours for £840.47.

system sure

Used by the largest food processors in the world, hospitals, restaurants, supermarkets and other manufacturing industries where rapid detection of contamination is crucial, the SystemSURE II allows companies to quickly determine the cleaning efficiency and hygienic status of surfaces and water, validate SSOP programs, ensure food safety, improve product quality and reduce costs.

Small, lightweight
Sensitive – detects down to 1 femtomole of ATP
100 programmable test locations
Stores 500 results
Simple to use, menu-driven
Operation from keypad
Results in 15 seconds
Self-calibration

How Can the SystemSURE II ATP Detection System Improve a Sanitation Program?

The SystemSURE II, in conjunction with the Ultrasnap sampling device, measures adenosine
triphosphate [ATP], the universal energy molecule found in all animal, plant, bacterial, yeast,
and mold cells. Product residue, particularly food residue, contains large amounts of ATP.
Microbial contamination also contains ATP, but in smaller amounts. After cleaning, all sources of ATP should be significantly reduced.
When ATP is brought into contact with the unique, liquid-stable luciferase/luciferin reagent in the Ultrasnap sampling device, light is emitted in direct proportion to the amount of ATP present. The SystemSURE II measures the amount of light generated and provides information on the level of contamination in just 15 seconds. The higher the reading, the more contamination present.
Assessing the cleanliness of a surface quickly after cleaning ensures contamination has been removed.
Depending on the industry, this system will help product quality, extend product shelf life, prevent cross-contamination, enable immediate corrective action and avoid recalls. ATP hygiene monitoring provides accurate and traceable verification of the hygienic status of a surface, which is a key component of a good sanitation program. ATP testing is a universally recognized tool used by the world’s largest and smallest companies for measuring the hygienic status of surfaces and water in order to ensure product consistency and safety.

Systemsure II Swabs (100 swabs)?  for £164.22 

ultra snap