Articles Tagged with: process
Home / Blog Archives

From Brew to Bottle: The Journey of Pasteurized Beer… Batch VS Tunnel Pasteurization

Introduction

  • Definition of pasteurization in the context of beer production
  • Significance of pasteurization in preserving beer quality and extending shelf life

The Brewing Process

  • Overview of the beer brewing process
  • Importance of sanitation and microbial control in brewing

Pasteurization Methods

  • Explanation of batch pasteurization
    • Description of batch pasteurizers and their operation
    • Advantages and limitations of batch pasteurization
  • Discussion of tunnel pasteurization
    • Description of tunnel pasteurizers and their components
    • Step-by-step process of tunnel pasteurization
    • Benefits and challenges associated with tunnel pasteurization

The Journey of Pasteurized Beers

  • Pre-pasteurization handling and preparation
    • Filtering and clarification
    • Carbonation and packaging considerations
  • Batch pasteurization process
    • Loading and heating the pasteurizer
    • Holding and cooling stages
  • Tunnel pasteurization process
    • Conveyor belt and temperature control
    • Heat treatment zones and dwell times
  • Post-pasteurization procedures
    • Quality control measures
    • Packaging and distribution

Benefits and Challenges of Pasteurization

  • Advantages of pasteurized beers
    • Increased shelf life and stability
    • Reduction of microbial contamination risks
  • Potential drawbacks and considerations
    • Flavor and aroma impact
    • Additional equipment and operational costs

Industry Trends and Innovations

  • Advancements in pasteurization technology
  • Emergence of alternative preservation methods
    • Cold filtration techniques
    • Non-thermal pasteurization methods

Conclusion

  • Recap of the journey of pasteurized beers from brew to bottle
  • Significance of pasteurization in ensuring beer quality and safety
  • Future prospects and potential developments in the field

Introduction

Beer, a beloved beverage enjoyed by many, undergoes a meticulous process from the brewery to the bottle. One crucial step in this journey is pasteurization. Pasteurization plays a significant role in preserving beer quality, extending its shelf life, and ensuring that it reaches consumers in optimal condition. In this article, we will explore the journey of pasteurized beers, focusing on the two primary methods of pasteurization: batch pasteurizers and tunnel pasteurizers.

The Brewing Process

Before delving into the intricacies of pasteurization, it’s essential to understand the beer brewing process as a whole. Brewing involves several steps, including malting, mashing, boiling, fermentation, and conditioning. Throughout this process, maintaining proper sanitation and microbial control is crucial to prevent any undesirable flavors or contamination.

Pasteurization Methods

Batch Pasteurization:

Batch pasteurization is a traditional method that involves heating packaged beer to a specific temperature for a predetermined duration. Batch pasteurizers typically consist of heating chambers and conveyors. The beer is loaded into the pasteurizer and heated, after which it is cooled and then released for packaging. While batch pasteurization is a well-established method, it has some limitations, such as longer processing times and higher labor requirements.

Tunnel Pasteurization:

Tunnel pasteurization, on the other hand, is a continuous process conducted in a tunnel-like machine. The beer bottles or cans move through the tunnel on a conveyor belt, passing through various temperature zones. Each zone is carefully controlled to ensure proper heat treatment. Tunnel pasteurizers offer faster processing times and higher efficiency compared to batch pasteurizers. However, they require significant initial investment and meticulous control to maintain consistent quality.

The Journey of Pasteurized Beers

Pre-pasteurization Handling and Preparation:

Before pasteurization, the beer goes through several essential steps. These include filtering and clarification to remove any sediment or impurities. Carbonation and packaging considerations are also addressed to ensure the beer’s quality and desired characteristics are maintained.

Batch Pasteurization Process:

In batch pasteurization, the beer is loaded into the pasteurizer, where it is heated to a specific temperature. This temperature effectively kills any potential harmful microorganisms. The beer is then held at that temperature for a predetermined time before being rapidly cooled. This process helps ensure the beer’s stability and extends its shelf life.

Tunnel Pasteurization Process:

Tunnel pasteurization involves a conveyor belt system that transports the beer through the tunnel pasteurizer. The temperature in each heat treatment zone is carefully controlled to eliminate any spoilage microorganisms while minimizing the impact on beer flavor. The dwell time in each zone is precisely calculated to achieve the desired level of pasteurization.

Post-pasteurization Procedures:

After pasteurization, quality control measures are taken to verify the beer’s microbiological stability and overall quality. Packaging, labeling, and distribution follow, ensuring that the pasteurized beer reaches consumers in a safe and consistent state.

Benefits and Challenges of Pasteurization

Pasteurization provides several advantages for beers:

Increased Shelf Life and Stability: Pasteurization extends the beer’s shelf life, allowing it to maintain its quality and freshness over an extended period.

Reduction of Microbial Contamination Risks: Pasteurization helps eliminate harmful microorganisms, reducing the risk of spoilage and potential health hazards.

However, there are considerations to keep in mind:

Flavor and Aroma Impact: Pasteurization can have a subtle impact on the beer’s flavor and aroma, which must be carefully managed to maintain the desired sensory profile of the beer.

Additional Equipment and Operational Costs: Implementing pasteurization requires specific equipment, such as pasteurizers and temperature control systems. These additional investments and operational costs need to be taken into account by breweries considering pasteurization.

As the beer industry evolves, advancements in pasteurization technology continue to emerge. Manufacturers are developing more efficient and precise pasteurizers, optimizing temperature control and reducing processing times. These advancements aim to enhance the pasteurization process while minimizing any potential negative effects on the beer’s quality.

Furthermore, alternative preservation methods are gaining attention. Cold filtration techniques, such as membrane filtration, provide an alternative to pasteurization by removing microorganisms without the need for heat treatment. Additionally, non-thermal pasteurization methods, such as high-pressure processing or ultraviolet light treatment, offer innovative approaches to ensure beer safety and stability while minimizing flavor impact.

Conclusion

The journey of pasteurized beers from brew to bottle involves crucial steps to preserve quality, extend shelf life, and ensure consumer safety. Batch and tunnel pasteurizers play a vital role in this process, each with its advantages and challenges. While pasteurization offers significant benefits, breweries must carefully manage factors such as flavor impact and additional costs.

With the continuous advancements in pasteurization technology and the emergence of alternative preservation methods, the beer industry is poised to explore innovative approaches to maintaining beer quality and safety. As consumers’ expectations evolve, breweries must adapt to these trends while staying true to the craftsmanship and flavor that make beer a beloved beverage.

By embracing the journey of pasteurized beers and staying at the forefront of technological advancements, breweries can ensure that their products consistently deliver a delightful drinking experience from the first sip to the last. Cheers to the science and artistry of pasteurization in the world of beer!

RESOURCES:

Brewer’s Association www.brewersassociation.org

The official website of the Brewers Association provides industry insights, technical resources, and publications related to brewing processes, including pasteurization.

The American Society of Brewing Chemists (ASBC) www.asbcnet.org

ASBC is a professional organization dedicated to brewing science and provides resources and publications related to various aspects of brewing, including pasteurization.

Master Brewers Association of the Americas (MBAA) www.mbaa.com

MBAA is another reputable organization focused on brewing science and provides technical resources and publications that cover various topics in brewing, including pasteurization.

The Institute of Brewing and Distilling (IBD) www.ibd.org.uk

IBD offers technical resources, publications, and articles related to brewing and distilling, including information on pasteurization.

The Brewing Science Institute (BSI) www.brewingscience.com

BSI provides technical support and consulting services to the brewing industry. Their website includes informative articles and resources related to brewing processes, including pasteurization.

“Brewing: Science and Practice” by Dennis E. Briggs, Chris A. Boulton, Peter A. Brookes, and Roger Stevens.

“Principles of Brewing Science: A Study of Serious Brewing Issues” by George J. Fix.

“Technology Brewing and Malting” by Wolfgang Kunze.

“Handbook of Brewing: Processes, Technology, Markets” edited by Hans Michael Eßlinger.

“The Oxford Companion to Beer” edited by Garrett Oliver.

Learn More About Tunnel and Batch Pasteurizing to Maximize Profits!

ABOUT PRO ENGINEERING / MANUFACTURING INC.

Trusted | Knowledge | Quality

We have been involved in pasteurizers since 1977.

PRO Engineering / Manufacturing Inc. has developed a range of small, medium, and large-sized tunnel & batch pasteurizers to fit the needs of BrewMasters and Beverage Makers. When our customers asked for more compact as well as full-size tunnel pasteurizers, PRO developed models to fit our customers’ needs. Then our customers needed a batch pasteurizer. We now provide batch pasteurizers; PRO is a business that continually innovates to meet customer needs.

For more than 40 years, we have been delivering solutions for beverage product shelf stability and consumption safety.

Edward A. Michalski CEO

Ed Michalski started his career in the beverage industry by designing stainless steel, higher flow, spray headers for Pabst Brewing. Along with the header design he also developed a process to produce the new headers.

Ed, along with his brother David, formed PRO Engineering / Manufacturing Inc. Based on what they learned by re-designing and refurbishing other manufacturers’ pasteurizers, Ed and PRO started to offer the pasteurizer marketplace superior new pasteurizers. PRO Engineering / Manufacturing Inc. has been designing and manufacturing great pasteurizers for over four decades.

For more information on tunnel and batch pasteurization contact PRO Engineering / Manufacturing, Inc. at [email protected] or call (414) 362-1500 and ask for Ed Michalski, CEO.

Partner with a PRO!… PRO Engineering / Manufacturing Inc.

Internal Resources:

What Is Thermal Pasteurization of Beer and Beverages?

Did you know that when you consume food or beverages that haven’t been properly pasteurized or pasteurized at all that you are more susceptible to kidney failure, or worse? So, why chance the safety of your products? If you’re a brewer, then you know that the quality of your beer is only as good as the ingredients and process used to make it.

The same goes for any other food or beverages that you may manufacture. Thermal Pasteurization is an innovative solution for brewers looking to improve their processes and ensure consistent quality in their products.

It is a great way to ensure that your products are safe for consumption. Let’s take a look at what thermal pasteurization actually is and discuss some of its benefits. After realizing how you could take your brewing production to a new level with this solution, we’re sure you’ll want some resources on how to get started with this process so keep reading.

So, What Is It And What Are The Benefits?

Thermal pasteurization is essentially a process that uses heat to kill the most harmful microorganisms in food and beverage products. There are many benefits of thermal pasteurization, especially if you run a brewery or manufacturing plant. To start with, the process is quick and efficient.

Unlike other methods like boiling, which takes up to six hours to kill bacteria in beverages that could be dangerous for human health (i.e., E-coli), thermal pasteurization only takes 15 seconds at 133°F/56°C to destroy harmful microorganisms such as yeast cells, mold spores, wild yeasts, lactic acid bacteria.

The most common way this heating method is applied is through hot water circulation. This is done where food products pass through stainless steel tubes before reaching packaging machines located behind closed doors on the same line. This means there will be no cross-contamination between products.

In addition to that, this process does not change the flavor of your product or its nutritional value. Another common method used by breweries and beverage manufacturers today is called High-Temperature Short Time (HTST). HTST uses heat exchangers with temperatures between 165°F-180°F (74°C-82°C) to achieve this effect.

It’s important to note that this process does not sterilize the product; it only reduces microbial levels below detectable limits. If there are no viable organisms left in your beverage, then you can say it has been “pasteurized” or “sterilized”. This is why it’s important to have a versatile piece of machinery when brewing.

Increased safety is perhaps one of the most known benefits. By using thermal pasteurization, you’re eliminating harmful microorganisms in your product, as we’ve mentioned. This will allow you to be sure that your customers are not at risk for any food-borne illnesses.

Want A Quick View Of More Benefits?

Breweries have been using different types of pasteurizers such as plate heat exchangers (PHE), tubular heating elements, batch tanks, among others depending on their production capacity and size which can vary from small-scale breweries to large industrial-size food and beverage manufacturers.

Hot water circulated around the product in stainless steel tubes for a short amount of time is all it takes to kill yeast cells, mold spores, wild yeasts, and lactic acid bacteria. If you haven’t already noticed, the main benefits are efficiency, innovation, and safety. Keep in mind that although the technique is highly innovative and efficient that it should not be used as a substitute for proper sanitation and hygiene practices.

There are additional benefits to utilizing a thermal pasteurizer in your brewing production. Let’s take a quick look at just a few more. Some of the other key benefits include;

Extended Shelf Life

This is another popular benefit that expert brewmasters enjoy about this solution. Thermal pasteurization helps to extend the shelf life of your product. This is because it kills what can cause spoilage or contamination. 

By using this process, you can ensure that your product stays fresh and delicious for longer periods.

Reduced Spoilage

Thermal pasteurization helps to reduce the amount of food or beverage that spoils, which can save businesses money. Any pathogenic organisms that could be present are eliminated during the process.

Improved Flavor And Quality

Thermal pasteurization helps to improve the flavor and quality of beverages. Keep in mind that your product will be able to keep even longer.

More Environmentally Friendly

Thermal pasteurization is a more environmentally friendly option than some traditional chemical pasteurization processes. It’s also a good thing to note that it does not produce any harmful byproducts.

How Exactly Does Thermal Pasteurization Work?

You might be wondering how the process actually works. We’re going to explain and then provide you with five simple steps to conduct the process itself. As you may already know, thermal pasteurization works by heating food or beverages to a specific temperature for a set amount of time.

This is what kills what may be harmful in the product. The process can vary depending on the type of food or beverage being pasteurized. Typically it involves heating the product to a temperature of 71.67 degrees Celsius (160 degrees Fahrenheit) for at least two seconds.

Overall, thermal pasteurization is considered to be a safe and effective alternative to chemical pasteurization processes. So, what are the steps when making beer?

Step One

Sanitize your equipment. This is important to starting off any production cycle because how you start off the process could determine the cleanliness of other materials used throughout the rest of the cycle.

Step Two

Boil water and add it to your fermenting container. The water will help to raise the temperature of the wort (unfermented beer) to the required level.

Step Three

Add the malt extract and stir well. Make sure that all of the malt extracts are dissolved in the water before you continue.

Step Four

Place the container in a thermal pasteurization bath and heat it to 71.67 degrees Celsius (160 degrees Fahrenheit). This is important because the temperature setting is meant to deactivate any microbial flora present.

Step Five

Remove the container from the thermal pasteurization bath and allow it to cool down. You can then add your yeast, which will ferment into beer over around one week.

Thermal pasteurization is an extremely versatile process that can be used in many different ways especially when making a few craft brews, running a full-scale production, or operating microbreweries.

Up Your Game as a Brewmaster

Thermal pasteurization is a great investment for any brewery. It can help to improve the quality and consistency of your beer, while also reducing the amount of time needed to brew it. Additionally, thermal pasteurization can change the art of brewing beer, making it an even more enjoyable experience.

If you are looking for a way to improve your brewery, then thermal pasteurization is something worth considering. Contact us today to learn more about this process and how it could benefit your business.

Match Your Production With Innovation

If you’re considering thermal pasteurization to up your game in the brewing industry you’re making a groundbreaking step in the way you perfect your craft. With over four decades of experience, PRO knows how to make your job simple. We also know how to bring fun back into your production by providing you with state-of-the-art equipment and expert steel design.

If you’re interested in learning more about what could benefit your brewing production, no matter your brewing needs, click here to learn more from PRO.

For more information on tunnel and batch pasteurization contact PRO Engineering/Manufacturing, Inc. at [email protected] or call (414) 362-1500 and ask for Ed Michalski, CEO.   

Edward A. Michalski Bio  
Ed Michalski started his career in the beverage industry by designing stainless steel, higher flow, spray headers for Pabst Brewing. Along with the header design, he also developed a process to produce the new headers.   Ed, along with his brother David, formed PRO Engineering/Manufacturing, Inc. 

Based on what they learned by re-designing and refurbishing other manufacturers’ pasteurizers, Ed and PRO started to offer the pasteurizer marketplace superior new pasteurizers.  

PRO Engineering/Manufacturing has been designing and manufacturing tunnel pasteurizers and batch pasteurizers for over four decades.  

ABOUT US:
PRO Engineering and Manufacturing was established in 1977 by Ed and Dave Michalski as a steel fabrication shop. For more than 40 years, PRO Engineering and Manufacturing, Inc. has been delivering solutions for beverage product shelf stability and consumption safety. As leading innovators in post-fill pasteurization, our skilled team offers the best in high-quality pasteurization equipment.

CONTACT US:
Phone: 414-362-1500 | Email: [email protected]

Location  |  YT Channel  |  Twitter  |  Facebook  |  LinkedIn

Previous Post: 
https://lnkd.in/gGYTf_Y

#beerindustry #hardseltzernews #hardseltzer #beverageindustry #beernews #alcoholindustry #brewery #craftbrewery #craftbeers #tunnelpasteurization #batchpasteurization #cider #beveragetrends #batchprocessing

Location: 11175 W Heather Ave, Milwaukee, WI 53224, USA

ABOUT US

PRO Engineering/Manufacturing, Inc. was established in 1977 by Ed and Dave Michalski as a steel fabrication shop. From this modest beginning, complete machine fabrication capabilities were quickly added followed by the installation of our own in-house engineering and design group.

Resources
Newsletter

Stay in touch with PRO's latest news!

By signing up, you agree with PRO's Privacy Policy and Terms.

MENU