CB-PD-BP-BRH-RR-001 Version: 3.4.

Brewhouse Approved on: 29.01.2024

Scope: ProjectOrLicense

General Document Information

Document Type Review Date Contact Creator Approver
Requirement & Proactive - Janusz Zawierucha Janusz Zawierucha Imantas Cepulis
Company Primary Secondary Functional Area Work Group
CB - Carlsberg PD - Production BP - Brewing & Processing BRH - Brewhouse Brewhouse
Explanation
-

Table of Contents
1. Abbreviations
2. BRH - Brewhouse
3. CB-PD-BRH-P004
4. CB-PD-BRH-P003
5. CB-PD-BRH-P001
6. CB-PD-BRH-P006
7. CB-PD-BRH-R004
8. CB-PD-BRH-R003
9. CB-PD-BRH-R010
10. CB-PD-BRH-R009
11. CB-PD-BRH-R011
12. CB-PD-BRH-P010
13. CB-PD-BRH-P011
14. CB-PD-BRH-P012
15. CB-PD-BRH-R008
16. RMT - Raw material
17. CB-PD-RMT-P024
18. CB-PD-RMT-P025
19. CB-PD-RMT-P026
20. CB-PD-RMT-P007

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21. CB-PD-RMT-P008
22. CB-PD-RMT-R024
23. CB-PD-RMT-P002
24. CB-PD-RMT-P003
25. CB-PD-RMT-P004
26. CB-PD-RMT-P023
27. MIL - BH Milling
28. CB-PD-MIL-R001
29. CB-PD-MIL-P002
30. CB-PD-MIL-P008
31. CB-PD-MIL-P009
32. CB-PD-MIL-R004
33. CB-PD-MIL-R006
34. CB-PD-MIL-P001
35. CB-PD-MIL-P003
36. CB-PD-MIL-P005
37. CB-PD-MIL-P006
38. CB-PD-MIL-P007
39. CB-PD-MIL-P010
40. MAS - BH Mashing
41. CB-PD-MAS-R001
42. CB-PD-MAS-P001
43. CB-PD-MAS-R013
44. CB-PD-MAS-P003
45. CB-PD-MAS-P004
46. CB-PD-MAS-P005
47. CB-PD-MAS-P010
48. CB-PD-MAS-P017
49. CB-PD-MAS-R005
50. CB-PD-MAS-P011
51. CB-PD-MAS-P009
52. CB-PD-MAS-P012
53. CB-PD-MAS-P014

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54. CB-PD-MAS-P015
55. CB-PD-MAS-R010
56. CB-PD-MAS-P007
57. CB-PD-MAS-P008
58. CB-PD-MAS-R012
59. CB-PD-MAS-P018
60. LT - BH Lautering
61. CB-PD-LT-R001
62. CB-PD-LT-P005
63. CB-PD-LT-P003
64. CB-PD-LT-P004
65. CB-PD-LT-R006
66. CB-PD-LT-R007
67. CB-PD-LT-R008
68. CB-PD-LT-R009
69. CB-PD-LT-P008
70. LRU - BH Last Runnings
71. CB-PD-LRU-R001
72. CB-PD-LRU-P004
73. CB-PD-LRU-P002
74. SG - BH Spent Grains
75. CB-PD-SG-P005
76. CB-PD-SG-P001
77. CB-PD-SG-P002
78. CB-PD-SG-P004
79. CB-PD-SG-P003
80. WB - BH Wort boiling
81. CB-PD-WB-R001
82. CB-PD-WB-R002
83. CB-PD-WB-P002
84. CB-PD-WB-P007
85. CB-PD-WB-P006
86. Quality Standards

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87. CB-PD-WB-R003
88. Late Hopping for Craft Breweries
89. CB-PD-WB-P005
90. CB-PD-WB-P008
91. WH - BH Wort handling
92. CB-PD-WH-R001
93. CB-PD-WH-R002
94. CB-PD-WH-R003
95. CB-PD-WH-P003
96. Quality Standards
97. CB-PD-WH-P001
98. CB-PD-WH-P002
99. CB-PD-WH-R005
100. CB-PD-WH-R004
101. CB-PD-WH-P006
102. LR - BH Loss Reduction
103. CB-PD-LR-P001
104. CB-PD-LR-P002
105. CB-PD-LR-P004
106. CB-PD-LR-P005
107. CB-PD-LR -R006
108. CB-PD-LR-P007
109. CB-PD-LR-P008
110. CB-PD-LR-P006
111. KPI - KPI Manual overall KPIs
112. CB-PD-KPI-R001

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Abbreviations

barg Pressure above atmospheric pressure

BRH - Brewhouse

Target

To produce beer by using materials which ensures a high quality of the wort.

Process standards

CB-PD-BRH-P004

The brewery has to develop the procedure for the introduction of the new crop raw materials in order to perform process parameters
adjustment if needed.

Refer to "New crop introduction protocol" under good practice.

CB-PD-BRH-P003

What

The brewery has to maintain two sets of recipes or one adjustable recipe for high and lowseason.

Why

To make sure that specific priorities respectively throughput and yield are kept.

How

This is valid in case of capacity constrains during high season.

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CB-PD-BRH-P001

Malt and adjunct: Based on the experience with the supplier, the brewery should have a plan of control analysis to monitor the
performance of each supplier in connection with group quality sampling plan.

CB-PD-BRH-P006

What

The brewery has to develop and establish golden rules for a brewing schedule construction.

Why

This is to ensure that every brewing schedule (brews sequence in a week) is built in such a way to avoid additional (out of routine) cleanings
which brings excessive water and energy consumption

How

Organic brews must be placed always at the beginning of brewing week (after weekly CIP), light stable beers at the beginning of a brewing
week or after intermediate cleaning, dark brew streams (Stouts, Porters) must be placed at the end of a week

CB-PD-BRH-R004

What

A centrifuge for hot wort clarification is not allowed

Why

This method will lead to wort oxidation and promotes shear forces which negatively impact beer filterability

How

Only whirlpool is allowed for hot trub separation.

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CB-PD-BRH-R003

What

The dosage of Calcium salts must effect in cold wort 40-70 ppm of Calcium ions for worts < 14 Plato and 70-100 ppm for worts >14 Plato

Why

Calcium ions must be in excess of oxalate which ensure its precipitation during fermentation and storage in order to avoid later haze and
gushing issues. It is needed also for yeast metabolism - enhancing yeast flocculation. Calcium stabilize a-amylase and acts as co-enzyme.
Excessive level of Calcium brings harsh and astringent character to beer.

How

Calcium can be dosed to mash and to wort kettle as chlorides or sulfides.

CB-PD-BRH-R010

What

Mash and wort transfers must be done always from the bottom.

Why

Other methods of transfers promote mash and wort oxidation.

CB-PD-BRH-R009

What

Transfer of wort from pre run vessel (PRV) to the Wort kettle (WK) must be performed as late as possible.

Why

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Too early wort transfer to the Wort Kettle (via preheater) will create excessive heat load to the wort which promotes furfural and 4-HMF
creation contributing to the staling/aged off flavor.

Valid for all brewstreams but all malt is the most exposed due to the fact that malt is already heat charged – in ideally situation the
Thiobarbituric acid index (TBI) of malt is below 14 but this is not specified so in reality it might be higher.

CB-PD-BRH-R011

What

Wort must not contain more than 40 % of glucose.

Why

Higher glucose level will lead to the abnormal polysaccharides uptake which leads to yeast stress and shift in the by-products production.

How

Revise the Bill of Material (BOM) and revise the enzymatic regime together with the enzyme supplier.

CB-PD-BRH-P010

What

Inner surface of mash tun and adjunct cooker must be free of black spots / scorched mash after emptying. Visual inspection must be done
weekly before the last brew.

Why

Scorched deposit is the evidence that mash is locally overheated which is harmful for taste stability.

How

Ineffective mixing or/and too high temperature of the heating medium is the root cause. Examine agitation regime, heating medium
temperature, rinsing and cleaning efficiency/frequency

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Bad example

Good example

CB-PD-BRH-P011

What

Wort entering the kettle must be dark and almost motionless until steam is applied. Weekly inspection must be done.

Why

Milky/foamy wort during filling of Wort Kettle is the symptom of wort aeration during transfer. Air ingress at high temperature is harmful
for taste stability since oxygen is reactive then and significantly decreases antyoxidative potential of wort/beer which makes the product
sensory less stable

How

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This phenomenon is created by air presence in transfer pipes LT/MF-PRV-WK when transfer pumps mix air with wort. Examine transfer
sequence to avoid air ingress specifically at the end of the process. Pipes must be filled with the liquid after transfer end - see Dry
Brewhouse Principle

Good example

Bed example

CB-PD-BRH-P012

What

Wort in a wort kettle must be dark and motionless during cast off process. The visual inspection must be done weekly

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Why

Foaming during cast off is a sign that boiling is still continued and local overheating occur which is harmful for taste stability

How

Ensure that steam supply is off once cast off begin.

A bad example

A good example

CB-PD-BRH-R008

What

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The CB engineering specifications must be used & followed when purchasing new equipment or systems.

Why

All COMStatements related to New Asset requirements rather than routine equipment operations have been moved from Operation COM to the appropriate Engineering
Specifications.

How

Any Challenges/Good Practices/Suggestions to the engineering specifications should be made using the COM Reference Number mentioned above & note the
Engineering Specification related specific assets.

All Engineering Specifications can be found at the following link:

Equipment & Buildings Engineering Standards

RMT - Raw material

Target

To ensure that the Raw Materials used for production of beer is of a high and consistent standard. The adjunct should not have any
negative influence on the final products in terms of quality and health. Further the standards should ensure a smooth and trouble-free
production process. Raw Materials must be provided by approved suppliers.

Extract in brewing material

Quantity of brewing materials used in the period based on the amount of materials delivered to the brewery corrected for changes in stock
levels (= stock primo + delivered – stock ultimo) multiplied by the actual extract content in the period. Extract of malt is calculated based on

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fine grist analysis, extract of brewing syrup based on the dry matter.

Process standards

CB-PD-RMT-P024

What

It is required to use for all malt Carlsberg always the malt Type A (Soluble Nitrogen < 0,68 %)

Why

Low soluble nitrogen will help to keep FAN in wort at the proper level. It is assumed that FAN should be at the level of 12 ppm / Plato.
Excessive FAN in wort makes your yeast happy but not all FAN will be picked up which can be later substrate for Strecker degradation in
beer during storage thus aged/staling off flavor can develop soon.

CB-PD-RMT-P025

What

If Carlsberg is produced with adjuncts (rice/barley) malt type B should be used.

Why

Too low FAN in wort (lower than 150 ppm) can lead to problematic fermentation. Also, it can cause very low beer pH as wort buffering
capacity will be much lower. The lower beer pH is, the faster staling processes are performing.

CB-PD-RMT-P026

What

Null-lox varieties will be helpful. - if all malt recipe.

Why

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These kind of varieties have LOX 1 and LOX 2 genes suppressed which means that there is almost no lipoxygenase activity which enzyme
promotes oxidation of fatty acids to carbonyls – the most famous is T2N (trans-2-nonenal) which is responsible for wet carton off flavor in
beer.

CB-PD-RMT-P007

The certificate of analysis (CoA) must include current Carlsberg group specification for all parameters mentioned.

CB-PD-RMT-P008

What

Enzyme application procedures described in the Enzyme Catalog must be followed. Potential need for other specific enzymes not
mentioned in the catalog must be discussed and approved with/by regional BP Lead and Regional Quality.

Why

To rationalize enzyme application in order to enhance extraction (yield) and improve the brewhouse throughput.

How

Please see in the attached good practice.

CB-PD-RMT-R024

What

The following calcium salts may be used in the brewhouse- see RWB for the ratio of salts

CaCl2
CaSO4

Why

Excessive chloride ions level contribute to the stress corrosion in stainless steel, have toxic effect on yeast and inhibit yeast flocculation
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Excessive sulphate ions may act as precursors for SO2 and H2S synthesis during fermentation

Sufficient calcium level is to precipitate oxalate ions during fermentation and provide it to yeast, as calcium promotes better flocculation.
Calcium in excess brings a harsh and astringent character to beer.

Calcium added to mash acts as coenzyme to alpha-amylase, enhance its thermal stability and lowers pH

How

Calcium dosage can be dosed 100% to mash (before enzymes dosage) or divided 70-80% to mash and 20-30% during wort boiling

CB-PD-RMT-P002

CaCl2 has a higher solubility than CaSO4 and should be used for mashing whereas the second one can be used for addition during wort
boiling. Use CaCl2 in a liquid solution to avoid corrosion. If the content of Mg2+ in the brewing water is high calcium addition should be
done with CaCl2 rather than CaSO4 in order to prevent bitter taste from MgSO4.

CB-PD-RMT-P003

What

H3PO4 is the standard due to the cost, but each brewery should calculate the total cost for dosing of calcium salts and acid to achieve the
target mash pH and calcium/pH specification in cold wort. Other food grade acids (lactic, hydrochloric, nitric, sulphuric) can be used but
H&S precautions must be obeyed - see respective MSDS

Why

Mash pH plays significant role in enzymatic action during mashing (i.e. Lipooxygenase suppression) and influence boiling process including
BU utilization. Depending on water hardness and calcium content lactic acid might be cheaper due to less calcium binding effect.

How

Local legislation must be followed. See attached Acid Conversion calculator . Validate volume of new acid (when shifting) in lab as buffering
capacity of the mash can differ.

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CB-PD-RMT-P004

The following additives and process aids may be used in the Brewhouse:

Carrageenan or Irish moss (Whirl-floc)

ZnCl2 or ZnSO4 for Zn2+ - addition, achieving minimum 0,15 ppm Zn2+ in the wort but not more than 1 ppm
MgSO4 and NaCl for specialty brands
Silicazoll dedicated for brewing industry

CB-PD-RMT-P023

The brewing liquor pH used for mashing in and sparging must be maximum 6,5 in order to limit extraction of high molecule polyphenols
from the grain husks. The lower the pH value the lower the extraction.

MIL - BH Milling

Target

To produce beer using a process which ensures a high-quality wort and brewhouse yield as well as minimizing energy consumption, hot
water surplus and the negative impact of oxygen.

Process standards

CB-PD-MIL-R001

The use of pre-milled malt is forbidden. Malt must not be milled earlier than 2 hours before mashing-in.

For Craft Breweries

Also for Craft Breweries malt should not be milled earlier than 2 hours before mashing-in. It is recommended that no pre-milled malt is
used. (Also for specialty malt however, due to shift management, exceptions are possible.)

CB-PD-MIL-P002

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What

The lowest roller gap for malt mill should be 0.4 mm for dry milling and 0.3 mm for wet milling. The lower gaps for wet milling can be
applied only, when conditioning water temperature is > 60 °C. The roller gap for adjuncts should not be lower than 0,3 mm (wheat/barley)
and 0,2 for rice.

Why

Lower mill gaps are beneficial for the optimization of the brewhouse yield, however it can distract the embryo and release fatty acids which
are accumulated in this part of the grain. Fatty acids can later in the process oxidize and cause off flavors in the final product. Lower mill
gap can be accepted when conditioning temperature is greater than 60°C.

How

The measuring must be done on hot rollers preferably just after the last brew.. Watch the supplier recommendation and respect it to not
endanger the equipment

CB-PD-MIL-P008

What

Roller gaps must be verified weekly. The check must be recorded.

Why

This is to detect a potential mill/rollers decalibration and potential negative impact on losses, if the gap is wider or quality if the gap is
smaller.

How

If the construction of the mill makes the measurement time consuming ( 1 hour) due to the long time for dismantling and accessing to the
rollers, indirect mill performance check/assessment must be in place. Such as grist analysis/composition or/and loss monitoring minimum
on a weekly basis.

The measurement must be done with means of a gap gauge just after milling (mill must be hot).

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CAUTION: LOTO principals must be in place.

Example for a gap gauge

CB-PD-MIL-P009

Sieves must be checked weekly. Hammers must be checked every second month.

CB-PD-MIL-R004

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Magnets must be checked and cleaned weekly (or in accordance with the local legislation if it is stricter).

CB-PD-MIL-R006

All scales for raw material must be calibrated in accordance with maintenance/calibration plan. Minimum once a year. Weighing sensors of
a silo, hopper must be verified minimum quarterly.

CB-PD-MIL-P001

Grist from 6-roller mill (lauter tun) or hammer mill (mash filter) should comply with the fractions indicated in the table below.

Laboratory analysis

Mesh Size Classification Lauter Tun Mash Filter (Meura)

≥1.25 contents of the 1.25 mm sieve Husk 18% ≤ 1%

<1.25 to ≥1.0 contents of the 1.0 mm sieve Coarse Grits 8%

≤ 9%
<1.0 to ≥0.5 contents of the 0.5 mm sieve Fine Grits 1 35%

<0.5 to ≥0.25 contents of the 0.25 mm sieve Fine Grits 2 21%

≥ 55%
<0.25 to ≥0.125 contents of the 0.125 mm sieve Flour 7%

<0.125 content of the pan Fine Flour 11% ≤ 35%

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CB-PD-MIL-P003

Adjuncts such as rice should be milled using dry milling. Barley can be milled both using dry or steep conditioning (wet) milling

CB-PD-MIL-P005

What

Malt and adjuncts(rice, barley, maize) should be milled by separate mills (applicable for lauter tun).

Why

A separate mill will enable to set milling parameters adequate to specific grain size, hardness, hull presence to optimize wort separation
process

CB-PD-MIL-P006

Minimum a dry 4 roller mill must be used for barley, rice and wheat milling.

CB-PD-MIL-P007

Conditioning water temperature for Wet or Conditioning Mill should be not less than 60°C but not higher than the mashing off temperature.

Craft Breweries

Depending on the size of the Craft Brewery the mill can be two to six roller-mills. Craft equipment standards document (WIP)

CB-PD-MIL-P010

What

Magnetic field power of any magnet in line must not be lower than 3000 Gauss (0,3 Tesla)
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Why

This is to ensure effective removal of any metal particles from the grain stream

How

The minimum power must be ensured by the magnet supplier (specification) and verified by a brewery min once per 5 years by a certified
contractor.

MAS - BH Mashing

Target

To produce beer using a process which ensure a high-quality wort and brew house yield as well as minimizing energy consumption, hot
water surplus and the negative impact of oxygen.

Process standards (100% malt)

CB-PD-MAS-R001

Wort from 100% malt and wort made from malt and barley must be produced by infusion mashing. Refer to the respective RWB.

For Craft Breweries:

For special wort type decoction is allowed.

CB-PD-MAS-P001

Heating during mashing is done with a heating rate of 1.0 – 2.0 °C/min.,

Be aware of surface fouling.

CB-PD-MAS-R013

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Temperature/pressure of steam used for heating should not exceed 130°C/3.0 bar.

For high temperature hot water, the temperature should not exceed 145°C/3.0 bar.

CB-PD-MAS-P003

As high season procedure, mashing off can be done at a temperature of up to 85°C to achieve a faster run off. For this procedure, the use of
thermostable alpha amylase in the mash is necessary as well as acidification and constant temperature of 85°C of the sparging water.

Energy consumption must be calculated against the benefit of increased brewhouse capacity.

CB-PD-MAS-P004

Adjuncts such as maize or rice with high starch gelatinization temperature can be used with the below parameters:

Mashing-in temperature should be min. 75°C

Water grist ratio: as low as possible e.g. 3.5:1
enzymes must be used instead of malt as part of adjunct mash
Thermo-stable a-amylase should be added
Separate mashing of remaining malt followed by mixing of adjunct and malt mashes or addition of cold water to adjunct mash to ca.
65°C followed by mashing in of malt part.
Rice/maize mash with thermo-stable a-amylase enzyme should have a rest at 83-85°C for 20 min.

CB-PD-MAS-P005

General salts dosage guideline :

Additives and process aids may be used if they are according to local legislation and food safety requirements.
The ratio of chloride to sulfate ions can influence the final taste of craft and crafty beers. High sulfate together with Na-ions can lead
to a harsh bitterness and low drinkability. Generally, higher Cl- ions are resulting in sweet finishes and SO4 more in dry finishes.
Brewing liquor composition must be taken in to account when deciding on salts dosing rates to obtain below anions ratio

Craft Type Cl : SO4 (ratio) in final beer

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IPA 1:2

Stout 2:1

Porter 2:1

PM Lager 1:1

CB-PD-MAS-P010

What

The mashing-in temperature (defined as the temperature of the mash during or just after mixing of malt/adjuncts and water) must be as
high as possible for the specific type of beer.

Why

Higher temperature is beneficial for the heat energy consumption but it restricts proteolytic enzymes activity.
This is to suppress lipoxygenase activity and later carbonyls formation.

How

The mashing-in temperature for all-malt mash must be 60°C – 2/+4°C.

Homogeneity of the mash has to be ensured at lowest possible agitation speed – however an agitation should be continuous
throughout

For Craft Breweries:

The mashing parameters can change in Craft Brewing due to special requirements of the specific product.
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The mashing-in temperature (defined as the temperature of the mash during or just after the mixing of malt/adjuncts and water) should be
as high as possible for the specific type of beer.

The mashing-in temperature for all-malt mash should be – 2/+2 °C related to the defined mashing-in temperature, during or just after
mixing of malt and water.

CB-PD-MAS-P017

What

Mashing in must be done in clump free manner – preferable pre-masher should be used.

Why

Clumps at the top of mash are symptoms of accelerated oxidation of mash – air access to the warm and wet malt/dust particles. The
below picture shows a negative example for clump formation in a mash tun.

How

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Dose the dust via a pre-masher to ensure proper wetting of the particles. Agitation speed during the whole mashing must be adjusted to
ensure a homogenous mash.

CB-PD-MAS-R005

What

If no null-lox malt is used, the mash pH must be kept at the level 5,2 + 0.2/ - 0.1.

Why

This is to suppress lipoxygenase activity and later carbonyls formation.

How

Use food grade acid to adjust the pH at the beginning of mashing in.

CB-PD-MAS-P011

When using rice/maize in a mash, it must be heated up to a maximum of 90°C and not allowed to boil.

The temperature used should be optimized according to the gelatinization temperature of the grist and the extraneous enzymes being used.

CB-PD-MAS-P009

Water grist ratio: as low as possible max 3:1.

CB-PD-MAS-P012

First wort extract must be > 21 °Plato for lauter tun and > 23 °Plato for mash filter.

CB-PD-MAS-P014

Specific gelatinization temperature provided by the malt supplier must be applied for the beta-amylase rest.
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CB-PD-MAS-P015

The mash is heated to 78 °C +/- 2 °C for mashing off..

CB-PD-MAS-R010

What

The mash must be Iodine negative prior to transfer to wort separation.

Why

This is to maximize the yield and avoid separation issues due to high viscosity and potential micro problem in the final product.

How

Follow the Sampling Plan and the official method described in the Group Quality documents according to the below color change chart.

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Iodine color change chart

CB-PD-MAS-P007

Addition of acid to set mash pH should be done to mashing in water.

CB-PD-MAS-P008
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The brewing liquor pH used for mashing in and sparging should be minimum 5,5 in order to limit corrosive power.

CB-PD-MAS-R012

What

The mash tun agitator can start running once it is covered by mash to minimize air ingress to the mash.The exception is Kolibri type
agitator:

Why

Too early start up of the agitator at mashing in promotes air ingress to the mash, which later will affect the taste stability of the final
product.

How

Check visually when the agitator starts to rotate and if there is no vortex appearing.

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CB-PD-MAS-P018

What

Mashing in time defined as milling start and mash tun (conversion vessel) filling end must not last longer than 30 mins.

Why

This is to ensure homogenous mash conversion

How

Adequate mill and pre-masher capacity must be ensured.

LT - BH Lautering

Target

To produce beer using a process which ensure a high-quality wort and brewhouse yield as well as minimizing energy consumption, hot
water surplus and the negative impact of oxygen.

Process standards

CB-PD-LT-R001

What

The temperature for the sparging water must be 78°C +/- 2°C when entering the separation equipment.

As high season procedure, mashing off can be done at a temperature of up to 85°C to achieve a faster run off. For this procedure, the use of
thermostable alpha amylase in the mash is necessary as well as sparging water acidification (pH 6) and constant temperature of 85 °C.

Why

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Proper sparging water temperature is necessary to maintain required run off speed and good extraction. The maximum temperature for
mashing off and sparging set by the equipment supplier can be applied (e.g. Meura Mash filter 85 °C) in order to accelerate the process
(higher temperature will lead to lower viscosity and therefore to faster run off). Thermostable alpha amylase avoids extraction of
unconverted starch in to the wort. No thermostable alpha amylase can lead to a negative iodine test of the wort, impact the filtration speed
downstream and creates colloidal and micro issues.

Lower sparging pH will decrease potential husky/grainy off flavor.

How

Energy consumption must be calculated against the benefit of increased brewhouse capacity, as the spent grains will be discharged at
higher temperature.

CB-PD-LT-P005

Last running's extract transferred to the wort kettle must be as low as possible. It decreases in proportion to volume of sparging water used.
If difference between Plato of first wort and full kettle is ≥ 6, last runnings must not exceed 1,3° Plato. Ex. First wort Plato is 20,5°full kettle
Plato is 14°-expected last runnings is <1,3. For high gravity brews -(Plato difference <6) expected last runnings Plato is <1,8°Plato.

Craft Breweries: Depending on the used ingredients and beer specifications this value may increase. General target should be as defined
above.

Crafty at Scale: The general target should be as defined in LT-R002.

CB-PD-LT-P003

Weak wort should be collected up to 0.3 °Plato and reused for the following brew.

The weak wort tank capacity must be fully utilized, in order to maximize the yield. If the brewhouse throughput has priority over the yield
the volume of the weak wort can be adjusted.

NOT APPLICABLE FOR CRAFT BREWERIES

CB-PD-LT-P004

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Hot water used for heating up the mash filter before the process should be collected and reused for example mashing in or sparging.

CB-PD-LT-R006

What

Air pipes supplying compressed air to the membranes of the mash filter must be checked regularly.

Why

If the membranes are broken or have a leak it will either create extract losses and heavy oxidation of the wort due to the air purge into the
mash filter.

How

Any signs of broken membranes must be investigated and checked weekly.

CB-PD-LT-R007

What

The first wort must be collected not more than until the surface of the filtration bed emerges.

Why

Collection of more wort is beneficial for the yield, but detrimental for the beer quality - it will suck in air – oxidation of the spent grain will
deteriorate the beer taste.

How

Stop the first wort collection, once the spent grains/filter bed start to be visible.

CB-PD-LT-R008

What

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Collected high quality wort – the turbidity of first wort during more than 60 % of time should be below 40 EBC.

Why

Turbid wort will carry over excessive volume of small particles which promotes later in CCTs intensive CO2 release which interferes with
proper yeast sedimentation. This will delay early and efficient yeast cropping.

How

Use an inline turbidity meter or set a proper time for the circulation prior start of the run off by offline turbidity measurement.

CB-PD-LT-R009

What

Wort separation must be done in an oxygen pick up free manner – so that Dissolved Oxygen in the first wort in the line to pre run vessel is
below 200 ppb.

Why

Oxygen pick up during separation will enhance wort constituents oxidation, which contributes to the beer staling/aged off flavor.

How

Perform DO measurements of first wort in the line to pre run vessel periodically (for example once a year), with a portable DO meter (must
be able to measure DO in high temperature liquids).

CB-PD-LT-P008

What

Excessive deep cuts must be avoided. Three per lautering run/cycle is maximumfor lager type brew streams

Why

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Deep cuts increase the content of oxygen intake/pickup by the physical work of the raking machine. Also, the deep cuts are causing higher
turbidity in the wort which brings some fatty acids into the fermenter. These fatty acids in combination with oxygen are causing Off Flavors.

How

Optimal mashing profile, proper enzymatic regime if legally allowed and good raw material selection.

LRU - BH Last Runnings

Reuse of Last Runnings, Flush Water, Press Water from Spent Grains and Trub

Target

To produce beer using a process which minimize the negative impact of oxygen, shear forces, lipid degradation and insures a high yield and
throughput, but low energy consumption process standards

Process standards

CB-PD-LRU-R001

Last runnings, press water from spent grain, trub and flush water must be stored at minimum 70°C and not longer than 48 hours.

Trub can be stored up to 96 h, if the temperature higher than 70 °C is ensured and an agitator in place. Heat energy consumption used for
the trub storage must be balanced with additional extract gain from trub.

CB-PD-LRU-P004

In case of recovery of last runnings, press water or flush water, they must be used as mashing-in water or latest as first sparge.

CB-PD-LRU-P002

What

Trub should be recycled.

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Why

This is to enhance brewhouse yield, as trub contains still extract and can contribute up to 0.9 % to the brewhouse yield.

How

By adding the trub back to the lauter tun during first half of sparging or in case of mash filters to the mash kettle just prior filling the
filters.Adding the trub to the mash kettle in case of a lauter tun will have a negative impact on the lautering performance, as the trub
particles can block the filter bed.

Validate trub recycling coming from "normal" brews and added back to a light stable brews, or from dark brews dosed back to pale.

See RWB as trub recycling can be forbidden in some recipes.

SG - BH Spent Grains

Target

To ensure that extract loss in the brewhouse process is kept at a minimum and that the spent grains are utilized in the most profitable way.

Quality standards

CB-PD-SG-P005

Soluble extract in spent grain must be as low as possible.

It decreases in proportion to volume of sparging water used.

If difference between Plato of first wort and full kettle is >= 6 °P, soluble extract must not exceed 0,7 % m/m (wet).

Example:

First wort Plato is 20,5 °P full kettle Plato is 14 °P- soluble extract is < 0,7 % m/m (wet).
For high gravity brews - (Plato difference < 6 °P) expected soluble extract is < 1,3 % m/m (wet) Good first and second wort separation
and full capacity weak work tank (if exists) utilization is necessary for this.

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Refer to Quality COM document "20.47.30 Soluble extract in spent grains".

CB-PD-SG-P001

Maximum extractable extract in spent grains 0.7 % m/m (wet). Good milling & enzymatic action needed for this.

See definition of soluble and extractable extract as well as analysis method in attached files below.

Quality COM document: "20.47.31 Total available extract in spent grains".

CB-PD-SG-P002

Percentage dry matter should reach 20% for lauter tuns and 28% for mash filters.

CB-PD-SG-P004

Blending of spent grains with trub and/or yeast should be discussed with the customer.

CB-PD-SG-P003

Maximum storage time should be one day.

WB - BH Wort boiling

Target

To produce beer using a process which minimize the energy consumption, but at the same time remove the DMS and minimize the
formation of Strecker aldehydes.

Process standards

CB-PD-WB-R001
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What

Boiling time is defined as starting when the wort is reaching 100 °C(at the sea level) and should be as short as possible (max. 60 mins) to
minimize the thermal load (valid for lagers).See specific RWB as some recipes might require different boiling time.

Boiling time should be optimized so that:

DMS in the final beer is < 45μg/l and sum of free DMS and DMSP is < 100 μg/l in cooled wort.
Satisfactory break formation is achieved
TBI in the final beer is <40 and is <60 in cooled wort

Why

The heat exposition time must be short enough to minimize the furfurals formation, but on the other hand be long enough to convert the
DMS-Precursors and evaporate the free DMS from the wort. Excessive heat load will contribute to accelerated aging/staling of the beer.

How

These variables must be measured at start-up of production, when new wort boiling equipment has been installed or at changes in wort
boiling procedure, or if DMS is picked up by the brewery taste panel.

CB-PD-WB-R002

Evaporation (total, by extract) must be as low as possible to achieve targets - maximum 4,5%.

See also Process standards and specifications for raw materials and wort handling.

Formula for calculation:

kettle f ullextract
Evaporation[%] = (1 − ) × 100
end of boiling extract

For Craft Breweries:

Wort should be boiled as short as possible and should not be longer than 65 minutes after the kettle is full.

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Evaporation (total, by extract) should be as low as possible to achieve targets - maximum 4%/hr. and preferable low steam pressure
boiling with less than 1.5 bar. However depending on recipe, spices etc. boiling time can be increased.

CB-PD-WB-P002

Energy saving systems should be considered (Capex) e.g.

vapor condensation,
vapor compression after a general optimization of the brewing process

CB-PD-WB-P007

What

If the isomerized hop extract is used it must be boiled not longer than 30 minutes preferably maximum 15 minutes.

Why

Longer boiling time of IKE/PIKE makes advanced conversion from cis-isomers to trans-isomers. Trans isomers are less stable and more
prone to the oxidation.

CB-PD-WB-P006

What

Cast off procedure time should be minimal or preferable avoided.

Why

Each additional minute at high temperature is detrimental for the beer flavor and taste stability.

How

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Immediately after steam valve shut down the transfer should commence.

Quality Standards

CB-PD-WB-R003

Temperature difference between heating medium and wort in the preheater must not be higher than 20 K.

Wort preheater must not be supplied directly with steam.

Late Hopping for Craft Breweries

Craft Breweries
Craft Breweries to choose a risk-free way of Late-hopping-closed circuit (HS, Quality, yield) without interfering to vapor pressurized vessels
manually, provided by key suppliers
Crafty at Scale
WB-R001 is still valid. Crafty – Late hopping in scale Breweries must be done with CB Standard Technologies (Quality, yield, HS etc.)
without interfering to vapor pressurized vessels. Manually closed circuit systems solutions of key suppliers can be used.
CB-PD-WB-P005

What

PH of wort must be adjusted at the end of boiling at the level 5,0-5,2.

Why

This is to standarize of pH at the beginning of fermentation. Dosing of acid prior boiling must be avoided because the lower pH is the lower
a-acid utilization is expected.

How

Food grade acid must be used f.ex. phosphoric or lactic - conversion calculator with list of acids is attached

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CB-PD-WB-P008

What

Free amino nitrogen (FAN) to original extract (OE) ratio must be around 12:1 but absolute FAN must be not lower than 150 ppm. FAN ratio
for propagation must be min 14:1

Why

Lower FAN will lead to yeast nutrition deficiency thus stuck or sluggish fermentation can happen – stressed yeast will produce excessive
amount of sulfuric compounds.

Valid for all brewstreams but all malt is the most challenging one since FAN can be easily to high if Soluble Nitrogen and Kolbach index are
too high. In adjunct recipes FAN can be easily too low so some adjustments in mashing profile or some enzymes might be needed to hit the
target.

How

Higher FAN levels can be achieved by implementing the following process adjustments, which must be aligned with the local legislation and
evaluated together with the local Quality department.

1. Use a Protein rest during the mashing to create more FAN by the proteinases from the malt.
2. Use legally allowed proteolytic enzymes according to suppliers recommendation.
3. Use FAN supplementations based on autolyzed yeast products (e.g. Fermaid B).

WH - BH Wort handling

Target

To produce beer using a process which minimize the energy consumption, but at the same time removing DMS and minimize the formation
of Strecker Aldehydes.

Process standards

CB-PD-WH-R001
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What

Wort is clarified using a whirlpool.

Stand time in WHP should be shorter than 20 minutes – the critical time is 25 minutes.

Why

Rest time in whirlpool, defined as the time from end of transfer to start of cooling,

Each additional minute at high temperature is detrimental for the beer flavor – alternatively precooling of wort to WHP below 90 °C is
recommended.

CB-PD-WH-R002

What

Transfer from the Wort Kettle to the Whirlpool must be shorter than 20 mins

Why

The 2 most likely causes is

1) If the pipe is not cleaned sufficiently the working diameter is becoming smaller and smaller which prolongs the transfer time.

2) There is scale build up in the wort cooler reducing the heat transfer and wort cooling is prolonged only when Whirlpool is a bottle neck in
the brewhouse

In both cases it contributes to excessive heat load and therefore low taste stability.i

How

Monitor the transfer time of each brew and investigate the reason, if the time exceeds the recommended value.For new installation the
design transfer time should be less than 10 min.

CB-PD-WH-R003
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The hot wort is cooled with a plate heat exchanger in maximum 60 minutes,
or maximum 80 minutes if the wort temperature in whirlpool is < 90 °C.

CB-PD-WH-P003

The hot wort is cooled to fermentation temperature for the products.

Quality Standards

CB-PD-WH-P001

If possible, the wort should be cooled to 85-90 °C just after boiling and prior to wort clarification e.g. by partial boiling to improve flavor
stability.

Craft Breweries and Crafty at Scale

Ideally, Craft/Crafty products should have a strainer between WHP and Wort cooler, in order to avoid blocking of Wort Cooler, or at
minimum a Wort Cooler backwash capability

CB-PD-WH-P002

The ideal dosing point for Zinc is between the Whirlpool outlet and the wort aeration.

CB-PD-WH-R005

What:

Cold wort is intensively aerated to reach 1 ppm per Platoof dissolved oxygen (DO) (+/- 2 ppm). The first brews are always aerated the last
brews not. The shorter the contact time of air with wort the better the aeration cannot last longer than 12 hours after first brew aeration
start. Minimum 30 % of last brews (volume) must not be aerated.

Why:

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This is to ensure proper oxygen supply to yeast during aerobic phase in order to secure sufficient sterols production for yeast cell division, as
well as to minimize the detrimental effect of oxidation of the wort constituents.

How:

The air flow rate effect must be validated min once per year for each gravity used with following procedure:

Fill the first brew to an empty fermenter without yeast

Wait for the next brew – around 1-2 h
Before the second brew filling, measure dissolved oxygen in first brew in the fermenter
Pitch the yeast to the second brew

In case DO is lower than target adjust air flow or/and counterpressure in an empty fermenter before first brew filling in order to hit the
target.

Yeast multiplication ratio must be controlled by number of brews aerated vs. not aerated in such a way that first brews must be always
aerated and last must be not aerated f.ex 6 brews goes to a fermenter, first 4 brews are aerated and last 2 not – aeration regime is 66%.

CB-PD-WH-R004

What

Total heat exposition time (temperature > 90 °C from transfer start from PRV to wort cooling start) must be not longer than 120 mins.

Why

High heat exposition time promotes heat aldehydes (furfural, 4HMF) creation which contributes to the staling/aged off flavor. This will lead
to a Thiobarbituric acid index (TBI) increase - expected values < 60 in cold wort and <40 in the final beer.

How

Transfer the wort from the pre run vessel to the kettle as late as possible (utilize the full capacity of the PRV). Keep the boiling time as short
as possible (preferably below 60 minutes). Minimize the cast off, transfer to the whirlpool and whirlpool rest time.

CB-PD-WH-P006

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What

Wort entering the Whirlpool should be dark and free of foam - this should be inspected weekly. The flow velocity should be controlled, and
be in range 3-3,5 m/s.

Why

Foaming during filling of whirlpool can be caused by presence of air in the WK-WHP pipe, which at high temperature accelerates wort
oxidation processes. This will decrease antioxidative potential of wort and later beer, which will promote staling processes. Too low inlet
velocity will make whirlpooling effect suboptimal, whilst too high inlet velocity will destroy the trub flocks thus separation will be less
effective. The more trub to fermentor the higher yeast multiplication and fatty acid residuals in beer what will promote stalling processes

How

Make sure that WK-WHP pipe is not empty before the transfer and control cast off pump run speed to ensure proper wort linear velocity at
the inlet to the WHP

A bad example

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A good example

LR - BH Loss Reduction

Target

To produce beer using a process which minimize losses on each stage of the brewing wort in the Brewhouse

CB-PD-LR-P001

Cold wort pipe must be flushed into Fermenting vessel with fresh water only after last brew to Fermenter.

In between the brews the wort stays in the line.

CB-PD-LR-P002

What

Emptying brewhouse vessels after water flushes, must be done with the "dry brewhouse" manner

Why

This is to avoid drainage of rinse water which can contain some extract also to minimize the water consumption.

How

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At the production mode, drainvalves remain closed so all flushes are transferred to the following vessel.

CB-PD-LR-P004

Check the mash for appearance of whole grains weekly.

CB-PD-LR-P005

Water volume used between the brews to the given fermenter must be limited to the volume of the wort cooler. This water must either go
to the fermenter during the following brew cooling or must be recovered back to the brewhouse. Extract and water loss must be prevented.

CB-PD-LR -R006

Manhole, sight glass, inspection light and safety switch in vessels must be in order

CB-PD-LR-P007

What

The tightness of Lauter Tun or Mash Flter must be checked in the regular intervals (set locally) - minimum monthly or more frequently
when extract loss increasing trend is observed

Why

Any leak of LT or MF will impact extract loss and oxygen pick up. It is experience that spent grain removal valve can be not tight and first
wort can be leaking to the spent grain bin.

How

The Leak Walk can be integrated with Gemba Walk. The critical points for inspection should be included in the Leak Walk check list

CB-PD-LR-P008

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What

False bottomvisual inspection must be done min yearly ( with lifting of the sieves) associated with a manual cleaning

Why

Quality of grains used for brewing and level of mineral impurities is the key factor. Small size stones coming with grains can get stuck in
sieves - this negatively affects separation performance (longer process time - more deep cuts) which effects of lower efficiency, higher
oxygen uptake and higher heat impact. Also due to inefficient cleaning of LT some run off pipe can be blocked with a sludge/silt which also
slow down the separation process

How

Above symptoms should trigger more frequent visual inspection of the false bottom. Also more advance method such as infrared camera
can be used to detect run off pipes with lower temperature which can indicate a pipe blockage. LOTO principles must be respected during
inspection and cleaning.

CB-PD-LR-P006

Any leakage of wort/water (valves, pumps, threads, etc.) must be investigated.Any leakage of utilities (water, steam, compressed air etc.)
also must be investigated

KPI - KPI Manual overall KPIs

CB-PD-KPI-R001

Cold wort extract must be used for Brewhouse yield analysis.

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