Control mashing and conversion in brewing
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
carry out water sourcing in accordance with the legal or regulatory
requirements, the organisational health and safety, hygiene and
environmental standards and instructions
identify the different types of water used in brewing
monitor the introduction of water into the brewing process
monitor the quality of a brewery water supply
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
monitor and control the health risks associated with legionella
bacteria in cooling water and service water
monitor and control water chlorination, softening, deionization and
de-aeration in a treatment plant
monitor and control effluent quality in terms of volume,
Suspended Solids (SS), Chemical Oxygen Demand (COD),
Biological Oxygen Demand (BOD), pH and temperature
reduce effluent loading from the principal effluent sources
Prepare for mashing and conversion
prepare for mashing and conversion in accordance with the legal
or regulatory requirements, the organisational health and safety,
hygiene and environmental standards and instructions
check product specifications at the right time
set up equipment according to specification
check that material for mashing and conversion is available and fit
for use
check that services meet requirements
start up the plant and check that it is running to specification
take action in response to operating problems
maintain communication in accordance with organisational
procedures
Carry out mashing and conversion
carry out mashing and conversion in accordance with the legal or
regulatory requirements, the organisational health and safety,
hygiene and environmental standards and instructions
use equipment and check that it is supplied with materials and
services
achieve the required output to the correct specification
check the product is transferred to the next stage in the
manufacturing operation
take action in response to operating problems within the limits of
your responsibility
maintain communication in accordance with organisational
procedures
Finish mashing and conversion
finish mashing and conversion in accordance with the legal or
regulatory requirements, the organisational health and safety,
hygiene and environmental standards and instructions
check the specifications to time shut down accurately
follow procedures to shut down equipment
deal with items that can be re-cycled or reworked
dispose of waste in line with organisational requirements
make equipment ready for future use after completion of the
process
maintain communication in accordance with organisational
procedures
complete all necessary documentation in line with organisational
requirements
Knowledge and Understanding
You need to know and understand:
the organisational health and safety, hygiene, environmental and
quality standards and instructions
the personal protective equipment required
the work area tools and equipment needed
why it is important to check the cleanliness of work area, tools and
equipment
what the typical usage volumes of water are as a ratio
what the water content of beer is
the essential uses of large volumes of water in a brewery
what the differences are, and typical uses of, product water,
process water and service water are
- at what points water is introduced into the process and the special
water quality needed at these points
- what the characteristics and quality of an ideal brewery water
supply are
what the sources of water for a brewery are
what the characteristics of different sources of water are in terms
of mineral ions content, consistency and possible nonmicrobiological contaminants
- the significance of legionella bacteria in cooling water and service
water and the health risks associated with the organism
- the basic principles of treatment plants for water chlorination,
softening, deionization and de-aeration
- what the nature and characteristics of effluent are from each
principal brewing operation
- 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
how to reduce effluent loading from the principal effluent sources
what the sequence of events are from raw material intake to
completion of the mashing and conversion process
- the operating principles of mashing/mash conversion systems,
including the cereal- cooking vessel
what the operational differences are between isothermal (mashtun) conversion and stepped temperature rise conversion vessels
what the typical times, temperatures and grist ratios used in the
conversion vessel are
the qualitative assessment of starch conversion
the operating principles of wort separation devices
why a particular wort separation device is used and the relevant
advantages and disadvantages of different devices
what the significance of cycle times are for brewhouse capacity
what the methods for the assessment of wort clarity/solids content
are
how spent grains are used as a co-product
how to deal with waste materials in accordance with
organisational requirements
- the need for records to be completed within agreed timescales
and to an agreed standard
- what should be communicated, to whom and why it should be
done
- the limits of your authority and the consequences of exceeding
them