Tully Hadley (MBrew) - IBD Asia Pacific Convention...

Tully Hadley (MBrew)

Cider Integration into a Large Scale

Commercial Brewery

Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section 2


OUTLINE

1. Process Overview

2. Considerations for the Brewery

3. Phase 1 – Blending and Packaging

4. Phase 2 – Fermentation and Clarification

5. Learnings

Project Scope

In 2014 Abbotsford Brewery embarked on a project to develop in house cider fermentation, blending and packaging capability

Objective was to produce a solution that was scalable and flexible enough to produce :

• 12 Existing Apple and Pear Ciders in Cans,

Bottles and Kegs

• NPD ready

• Planning cycle similar to beer

• Meet quality attributes

• Integrate seamlessly with existing

production


CIDER PROCESS OVERVIEW


Base Production

Fermentation Filtration Storage Blending Packaging


Product

Water

Pasteurising

Fermentation

Clarification

Storage

Final

Filtration

Final Product Packaging

Fruit Juice

Concentrate

Fruit Juice

Adjunct

Food Acid

Yeast

Nutrient

Other

Yeast Oxygen

DAW

CO2

Other

Yeast

Propagation

CIDER PROCESS OVERVIEW

PHASE 2

Onsite

Fermentation

and subsequent

processing

PHASE 1

Tankering of

cider base and

subsequernt

packaging


CONSIDERATIONS FOR THE BREWERY

Dried yeasts are good quality and produce many flavour profiles

Apple Juice lacks essential nutrients for repitching

“Pitch and Ditch” methodology is expensive at large scale.

Hygiene

Dried yeasts specify Lactic Acid bacteria <105 CFU/g

Hygienic Yeast Propagation process is essential

Beware “Killer Factor Active” CIP philosophy to avoid cross contamination

Yeast

Cider is very seasonal – flexible system capacity essential

Easy to automate – continual vs batch

Collect the CO2

Capacity

Maximise existing assets where possible – the process is similar

Cider is acidic – beware of existing civil works

Existing

Assets


PHASE 1 Raw Material

Receival

• Cider Base

• Juice and

Adjuncts

Raw Material

Storage

• Cider Base

• Juice and

Adjuncts

Blending • Blending

• Dilution

• Carbonation

Packaging • Analysis

• CIP


PHASE 1 Installation of raw material receival and storage capability


BLENDING

Existing FV

Existing SV

Existing FV

Existing

BBT

CO2 DAW

Juic

e

Ma

lic

FLA

VO

UR

S

Dilution/Carbonation Storage Cider BBT Dosing Equipment

Diluted and carbonated

through existing filtration

assets

Existing BBT

and controls

are sufficient

Existing storage

assets are

suitable for

storage of cider

Variable viscosity and

flowrate dosing equipment

required for dosing flavours

and aromas


PHASE 1 Installation of Blending capability


PHASE 1 Analytical Capability Routine Analysis

Alcohol, SG, PE, RE ( Densitometer)

Colour (Spectrophotomter)

Gravity (Densitometer)

pH (pH meter)

CO2 (CarboQC, cDGM)

Total Acidity (Titrino)

Free SO2 (Titrino)

Total SO2(Titrino)

Ionics – Fe, Cu, Zn, Ca, Mg, K, Na (ICP)

Ionics – Cl, SO4 – (HPLC)

Haze 90⁰ and 25⁰ (Sigrist)

Other Analysis

Volatile Acidity (Gas Chromatography)

Total Fermentable Carbohydrates (HPLC with RI)

Diacetyl (Gas Chromatogrpahy)

Sulphides (GCSCD)

Volatiles (Gas Chromatography)

Sorbitol (HPLC)

Organic Acids - HPLC


PHASE 2 Fermentation

Base Production

• Blending

• Pastuerising

Yeast Propagation

• Hydration

• Propagation

• Pitching

Fermentation • CO2 Collect

Separation

Clarification •Filtration

•Diafiltration


FERMENTATION BASE PRODUCTION

Apple Juice FV

Dry yeast

Oxygen

Sterile

H2O

Existing

FV

Additives:

Zinc,

DAP,

Yeast food

Juice

Tanks

Delivery

Yeast Foods Base Pastueriser

Existing FVs

and control

are sufficient.

Unloading to

storage vessel Base is

pastuerised to

ensure sterile

product to yeast

prop and

fermentation.

Cooling and

oxygenation

inline

Juice

Tanks

Yeast nutrients

proportionately

dosed to

predetermined

recipe setpoints

Yeast Injection

Propagated

yeast injected

inline to achieve

recipe pitching

rate

Steam,

refrigerant

Water


PHASE 2 Fermentation Base production

Proportional Dosing of Yeast Nutrients Flash Pasteuriser for base production


PHASE 2

Yeast Propagation

For consistency and cost, propagated yeast was favourable

Production cycle is 1 fermenter per week = 1 propagation per week

Traditio al eer yeast propagatio pro ess u suita le

Had to design a yeast propagation process to deliver pitching quantity of cells in a

4000hL fermentation every week.

Asia Pacific Convention 2018 | Wellington, New Zealand Institute of Brewing and Distilling Asia Pacific Section

17

YEAST PROPAGATION

Dry yeast

Oxygen

Sterile H2O

Existing FV

Propagation Rehydration

Cooling with oxygenation

and agitation through

recirculation to build

biomass.

Rehydration of

Dried Yeast, under

aseptic conditions.

O2

Pastuerised

Juice

Pitching

Propagated Yeast is

pitched to achieve recipe

setpoint cell count


PHASE 2

0

50

100

150

200

250

0 5 10 15 20 25 30

Cells (x 106)

Hours

Yeast Cell Count – Cider Propagation


PHASE 2

Hydration vessel with:

• CIP and Steam sterilisation

• Laminar flow

• Ozone environmental sanitation


PHASE 2

Laminar flow conditions to ensure aseptic

conditions

Yeast hydration access hatch – CIP and

steam sterilisation


PHASE 2

Yeast Propagator Recirculation with online oxygen monitoring

and injection


PHASE 2

Fermentation

• Uses existing (modified) fermenter vessels

• Normal beer (Ale) fermentation temperatures and pitch rates

• Normal fermentation profile (~200 hrs)

• Yeast is non flocculant


PHASE 2 DAY

SG°/°C

25

20

12% 15

11%

10%

9%

8% 10

7%

6%

5%

4% 5

3%

2%

1%

0% 0

222 228 234

1.030°

1.085°

1.080°

1.075°

1.700°

1.065°

1.060°

12 174

1.025°

1.055°

1.050°

1.045°

1.040°

1.035°

1.020°

1.015°

1.010°

1.005°

1.000°

0.995°

0.990°

5

18 24 30

6

66

2 3

144 150

4

156 162

0 1

168

1.100°

1.095°

1.090°

108 114 120 126 132 13872 78 84 90 96 10236 42 48 54 60hrs 6

9

ALC

TEM

P

7 8

180 186 192 198 204 210 216

SG

% ALC

Normal fermentation profile with little to no lag phase


PHASE 2

Cider Membrane Filtration

• Fermented cider base has low protein and polyphenol content

• Chill haze is not an issue

• Cider can be clarified (filtered) once fermentation is complete.

• If using fresh pressed apples, additional treatments are required to clarify.


PHASE 2

Cider Me ra e Filter to produ e right ider ase


PHYSICAL PROCESS SEPARATIONS

FERMENTER

Fermenter should be physically isolated on the CO2

Collect and Vent lines to avoid cross contamination into

other fermenters.

STORAGE VESSEL AND BBT CO2 TOP PRESSURE

Top Pressure systems for storage vessels and BBTs were

separated to ensure no flavour carryover between beer

and cider.


LEARNINGS It is possible to achieve micro free fermentations using dried yeast

Invest in aseptic yeast propagation process

-10

40

90

140

190

240

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Sp

oil

ag

e O

rga

nis

ms

CF

U

Month

Cider Fermentation Spoilage Organisms


LEARNINGS

• Design in flexibility from the start – innovation is constant

• Fermentation is very reliant upon FAN and nutrient availability

• Extract loss is good – but take note of malic acid

• If treated with the care and attention that we give to beer – great product

quality and product consistency will be the reward.

Acknowledgments

• Sam Seward (Engineering)

• Andy Dzubiel (Engineering)

• Michael Pecar (Engineering)

• Jaideep Chandrasekharan (Chief Brewer)

• Grahame Ellis (Plant Manager, Campbelltown Cidery)


IBD PPT – Final Slide

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