MICROBREWQuality Control and Beer Science at Jack’s Abby Brewing

Kate Steblenko

Jack’s Abby Brewing• Started in 2011

• 2011 – 500 bbls• 2012 – 1,500 bbls • 2013 – 6,000 bbls• 2014 – 14,000 bbls• 2015 – 22,000 bbls• 2016 – 50,000 bbls?

• New Brewery opening this winter• ~5X bigger• Lab space 60 ft2 270 ft2

The New Space

Jack’s Abby Instagram

QA/QC TEAMThe highest in quality

Kate SteblenkoBeer Scientist

• UVM 2013 graduate

• BS in Biochemistry and molecular genetics

• Resident nerd

Tim WilsonQuality Manager

• Siebel Institute of Technology & Doemens Academy – 2007

• Runs sensory program

• Enjoys Corona

Sarah PottQA/QC Technician

• Part time kegger

• Part time lab rat

• Full time push up champion

• Graduate of Drop-In’s American Brewers Guild program

TasksDaily

•Forced fermentations

•Cell counts•Microbiology•Fill heights•Dissolved Oxygen

Weekly/Monthly

•Sensory Education

•Grist analysis

Forced Fermentations•Naturally carbonated beers•Bung timing •Batch to batch consistency•Wort quality•Yeast health

Cell CountsCurrent

• Adequate pitch• Lager – 1.5 x 107 cells/ml/

• Underpitching and overpitching

• Yeast health, growth, and viability

Future• Yeast propagation system

• Slurry counting• Appropriate pitch

• 1.5 x 106 cells/ml/°P OG

• Flow meter on prop system pitch exact volume needed

Microbiology Media

• HLP• Anaerobic in 15 ml conical

tubes• Detects lactobacillus and

pediococcus

• WLN/WLD• Brewery related

organisms• Add cycloheximide to

inhibit Saccharomyces species

Frequency• Sampling

• Day 1• Day 7• Brite tank• Finished Product

• Plating• Every 1-2 days

Aseptic Technique• You do not NEED a sterile hood! (although it REALLY helps!)

• Requires an undisturbed air space• Limit movement in the

air space as well as people moving around it

• Flame everything

http://files.shroomery.org/files/13-20/874348262-Aseptic_Convection.gif

Plating – Past and PresentPast

• Plate 1 mL of beer in process onto large petri dish

• Allow time to soak into plate• Filter ~25 ml packaged

beer through a 0.45 µM membrane• Use autoclavable, glass

filtration system

• Invert and incubate 4-6 days at 30°C, 10% CO2

Present

• Filter 10 ml of beer in process through a 0.45 µM membrane

• Biosart 100 monitors• Plate onto small petri dish• Invert, incubate

anaerobically 4-6 days at 30°C, 10% CO2

Anaerobic Incubation SystemsBD GasPak™ EZ Container

System BD GasPak™ EZ Pouch System

www.bd.com

A busy day in

the hood

Fill Heights•At least 3 months of data for TTB•Use weights, final gravities, and math•Adjust filler accordingly

• Underfill – unsellable• Overfill – loss of product• Total Packaged Oxygen

Dissolved Oxygen• Centrifugation

• Adjust clamps, gaskets

• Before bottling• Compare to post centrifuge levels• Assess oxidation levels• Purge with extra CO2

• Throughout the bottling run• Adjust FOB

Sensory• Monthly sensory training• Off flavors• Warm aged bottles from

time-points over the past few months

• Employee education

www/pinkbootssoiety.com

Grist Analysis•Analyze each new silo delivery•Test sieve

• USA Standard test sieve• No. 10 (2.00 mm) – No. 100 (150 µm)

•Still establishing specs

Sizing up the ProgramOut with the old In with the new!

Our First Investment

Tuttnauer 2450Fits 4-6 500 ml media bottles

Future Improvements • Liquid media

• Saves time, money, resources• Only works with Biosart 100 monitors

• Larger hood space• Less turbulence • More room to move• Permanent hood installation

• Manifold for vacuum pump• Multiple samples at once

New Lab, New Tools• UV-Vis Spectrophotometer

• IBU• Color• Diacetyl

• Alcolyzer• Alcohol percentage• Density• pH• Calories

• Dissolved O2 and CO2 meters

uk.hach.com

www.antonpaar.com

ca.hach.com

Cheers!Kate Steblenko

kates@jacksabbybrewing.com