Control mashing and conversion in brewing

URN: IMPBW102
Business Sectors (Suites): Brewing
Developed by: Improve
Approved on: 2019

Overview

This standard is about the skills and knowledge needed for you to control mashing and conversion in brewing. This standard details the skills and understanding needed when manufacturing part or finished products from a raw material. It details the skills required to start up, run and shut down equipment, as well as being able to take the appropriate action should operating problems occur. It is also about working to product specifications and production schedules. Complying with and understanding health and safety, food safety and organisational requirements are essential features of this standard. It details the skills needed to monitor and control the water sourcing process in brewing. It also covers the different types of water and water sources used in brewing and the impact they have on legal, organisational, health and safety and environmental regulations. An understanding of the principles of sourcing water, water treatment and effluent in brewing is required. It covers the regulatory requirements, water sources and quality, water characteristics and treatment, and effluent control. This standard also covers understanding the principles of mashing and conversion in brewing. It covers the conversion of starch into simple sugars in the mash, the role and function of enzymes, the significance of time and temperature in mashing and conversion and the significance of mineral salts in mashing. This standard is for you if you work in brewing and are involved in mashing and conversion in brewing.


Performance criteria

You must be able to:

Carry out water sourcing in brewing

  1. carry out water sourcing in accordance with the legal or regulatory

    requirements, the organisational health and safety, hygiene and

    environmental standards and instructions

  2. identify the different types of water used in brewing

  3. monitor the introduction of water into the brewing process

  4. monitor the quality of a brewery water supply

  5. identify the sources of water for a brewery and the characteristics

    of each in terms of mineral ion content, consistency and possible

    non-microbiological contaminants

  6. monitor and control the health risks associated with legionella

    bacteria in cooling water and service water

  7. monitor and control water chlorination, softening, deionization and

    de-aeration in a treatment plant

  8. monitor and control effluent quality in terms of volume,

    Suspended Solids (SS), Chemical Oxygen Demand (COD),

    Biological Oxygen Demand (BOD), pH and temperature

  9. reduce effluent loading from the principal effluent sources

    Prepare for mashing and conversion

  10. prepare for mashing and conversion in accordance with the legal

    or regulatory requirements, the organisational health and safety,

    hygiene and environmental standards and instructions

  11. check product specifications at the right time

  12. set up equipment according to specification

  13. check that material for mashing and conversion is available and fit

    for use

  14. check that services meet requirements

  15. start up the plant and check that it is running to specification

  16. take action in response to operating problems

  17. maintain communication in accordance with organisational

    procedures

    Carry out mashing and conversion

  18. carry out mashing and conversion in accordance with the legal or

    regulatory requirements, the organisational health and safety,

    hygiene and environmental standards and instructions

  19. use equipment and check that it is supplied with materials and

    services

  20. achieve the required output to the correct specification

  21. check the product is transferred to the next stage in the

    manufacturing operation

  22. take action in response to operating problems within the limits of

    your responsibility

  23. maintain communication in accordance with organisational

    procedures

    Finish mashing and conversion

  24. finish mashing and conversion in accordance with the legal or

    regulatory requirements, the organisational health and safety,

    hygiene and environmental standards and instructions

  25. check the specifications to time shut down accurately

  26. follow procedures to shut down equipment

  27. deal with items that can be re-cycled or reworked

  28. dispose of waste in line with organisational requirements

  29. make equipment ready for future use after completion of the

    process

  30. maintain communication in accordance with organisational

    procedures

  31. complete all necessary documentation in line with organisational

    requirements


Knowledge and Understanding

You need to know and understand:

  1. the organisational health and safety, hygiene, environmental and

    quality standards and instructions

    1. the personal protective equipment required

    2. the work area tools and equipment needed

    3. why it is important to check the cleanliness of work area, tools and

    equipment

    1. what the typical usage volumes of water are as a ratio

    2. what the water content of beer is

    3. the essential uses of large volumes of water in a brewery

    4. what the differences are, and typical uses of, product water,

    process water and service water are

    1. at what points water is introduced into the process and the special

    water quality needed at these points

    1. what the characteristics and quality of an ideal brewery water

    supply are

    1. what the sources of water for a brewery are

    2. what the characteristics of different sources of water are in terms

    of mineral ions content, consistency and possible nonmicrobiological contaminants

    1. the significance of legionella bacteria in cooling water and service

    water and the health risks associated with the organism

    1. the basic principles of treatment plants for water chlorination,

    softening, deionization and de-aeration

    1. what the nature and characteristics of effluent are from each

    principal brewing operation

    1. what the principle components of effluent quality are in terms of

    volume, suspended Solids (SS), Chemical Oxygen Demand

    (COD), Biological Oxygen Demand (BOD), pH and temperature

    1. how to reduce effluent loading from the principal effluent sources

    2. what the sequence of events are from raw material intake to

    completion of the mashing and conversion process

    1. the operating principles of mashing/mash conversion systems,

    including the cereal- cooking vessel

    1. what the operational differences are between isothermal (mashtun) conversion and stepped temperature rise conversion vessels

    2. what the typical times, temperatures and grist ratios used in the

    conversion vessel are

    1. the qualitative assessment of starch conversion

    2. the operating principles of wort separation devices

    3. why a particular wort separation device is used and the relevant

    advantages and disadvantages of different devices

    1. what the significance of cycle times are for brewhouse capacity

    2. what the methods for the assessment of wort clarity/solids content

    are

    1. how spent grains are used as a co-product

    2. how to deal with waste materials in accordance with

    organisational requirements

    1. the need for records to be completed within agreed timescales

    and to an agreed standard

    1. what should be communicated, to whom and why it should be

    done

    1. the limits of your authority and the consequences of exceeding

    them


Scope/range


Scope Performance


Scope Knowledge


Values


Behaviours


Skills


Glossary


Links To Other NOS


External Links


Version Number

2

Indicative Review Date

2024

Validity

Current

Status

Original

Originating Organisation

Improve

Original URN

imppo212 (skill), impbw102k

Relevant Occupations

Food Preparation Trades, Manufacturing Technologies, Plant and Machine Operatives, Process Operatives, Process, Plant and Machine Operatives

SOC Code

8111

Keywords

Food; Drink; Manufacturing; Brewing; Conversion; Mashing; Starch; Grist