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Surface Finish of Brewing Process Vessels

Conference Paper · March 1993

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StainEess $teel Vessels with Dark Residue on lnternal Surfaces.

Report prepared by John Cluett

During the commissioning of 12 x 3000 hl new stainless steel fermenters at SAB

Prospecton Brewery in 1991, the vessels were degreased, passivated with a 30o/o
Nitrlc Acid solution and acid cleaned all through the CIP plant. After all three
surface treatments, the internal surfaces were inspected with cotton wool swabs
and found to have a dark residue. The brewery brewing and quality managers
refused use of these vessels until the dark residue was eliminated.

After an exhaustive investigation of the surface residue using EDAX, the cotton
wool swab was found to contain stainless polishing material residue. A series of
solvents was tested on the stainless steel to assess which one would remove the
dark contamination that, by using lnfra Red Spectrum analysis, was found to be
"Plasticizer" from the plastic sheeting used to protect the surface after polishing.
TCE solvent was sprayed through high-pressure jets introduced from the top
manhole and recycled back into tank until the contaminants was removed from
the internal surface of the vessels. After TCE spraying, all vessels were tested by
swabbing internal surfaces and found to be clear of the dark residue and fit for
brewing. Application of TCE must be done by an experienced contractor.

Cotton wool swabs: The following picture shows the swab with the dark residue
on the left and the swab after treating the stainless steel surface with TCE.
EDAX showed the following peaks:

Fsr*I rri qe: r+fg

#91

Plasticizers: are usually added to plastics to keep them from becoming brittle at
room temperatures. Dialkyl phthalates are commonly used for this purpose and
in the past decades have become amongst the most widely dispersed of all
environmental pollutants. Phthalate plasticizers have been detected in the fat of
antarctic penguins. (Extract for Synthetic Polymers).

The following photo shows the Plasticizer extracted by TCE from the fermenter.

TGE: Trichloroethane. syns: 1,1,1-trochloroethane, methyl, chloroform.

CHsCCLs. This material needs very careful handing and the MSDS must be
carefully revie d to ensure all safety condition of use are applied.
Conclusion and recommendations.

1. Stainless steel vessels internal surfaces should not be polished as it adds

to the overall cost of fabrication.
2. ln the case that internal surfaces are polished, only use paper sheets to
protect the surface and NO adhesive plastic sheets must be used for this
purpose. ln the case of rolled stainless steel used for tank fabrication, the
steel mill must supply these rolls with paper sheet inlays.
3, The internal surface of stainless steel vessels used for brewing and
storage of beer must be tested by using swabs soaked in distilled water
to assess if there is any dark residue as shown in the picture above. ln
case of any dark residue found, these vessels must be treated and
cleared of that residue before being released for dispatch to the brewery
site.

15 December 2008
 SURFACE FINISH OF BREWING
PROCESS VESSELS

H. BARBER J.D. CLUETT

SOUTH AFRICAN BRE\1tsRIES OPERATIONAL ENIIANCEMENT
PROSPECTON, DURBAN PROGRAN{MES (PTY) LTD
JOIIANNESBURG

THE INSTITLTTE OF BREVITNG CENTRAL AND SOUTHERN AFRICAN

SECTION.
FOURTH SCIENTIFIC AND TECHNICAL CONVENTION
LORD CILARLES HOTEL, SOI\{ERSET VIEST. SOUTH AFRICA
28 FEBRUARY - 4 T,,IA.RCH 1993
 Page 1

Abstract:
The requirement by Brewers to have a surface finish which facilitates the
process, allows for effective cleaning and ensures no contamination of the
product, present important challenges to fabricators of Brewing equipment. The
specification to achieve the required surface and the profiles obtained on
stainless steel and coated finished surfaces after fabrication, are reviewed and
shown with aid of micro-photographs.

Comparisons between coated surfaces (epoxy lined) and stainless steel surtaces
as seen on 28 milled surface, mechanical polishing and electro polishing,
indicate a significant difference between all these surface profiles. The ability to
clean vessels with these different surfaces of soil and bio film depends on the
relative "roughness" of the material and the C I P process used. The most cost
effective system needs to be life cycle costed, taking into consideration initial
capital costs and operational factors to achieve a totally clean surface.

and quality indicators

The criteria to evaluate the internal surface finish and the corresponding quality
indicators are summarised as follows:

Criteria Qualitv indicators

O Process enhancement ,........ Evenflow, self draining, yeast
slipability, cleanability

O lneft surface No contamination to product

Resistance to process- ...... No corrosion, elimination of surface

CIP conditions soil during ClP.
Permanent surface No delamination or breakdown of
coating.

O Predictable surface Surface finish measurement (eg Ra)

profile after fabrication

C Free of fabrication contaminants No fabrication residues/solvents

These criteria should also peftain to internal surfaces of pipes and fittings.
 Page 2

The method of measurement is based on the surface texture of the material which
result from the marks left by action of the fabrication process - such as grinding
material, rolling mills and spraying process on coated vessels. The primary
texture can be measured by various constants, as for example Ra, which build
up an accurate picture.

The surface measurement most commonly used is the arithmetical average (Ra)t
expressed as:-
Ra: hl+h2+h3 hn
L
where h is the height of the profile above or below the centre line at points at unit
distances apart. L Units = Sampling length.

Samples of surfaces measured expressed as Ra, on materials used for brewing

process vessels are as follows. The two different methods of analysis
(SURTRONIC 3 and HOMMELTESTER PsD (s) ) for Ra valves were carried out on
different sets of samples.

Epoxy lined surface treatment on fermenting and storage tanks :

SURTRONIC 3. Ra 0,09 prm. (2)

HOMMELTESTER PSD Ra 0.07prm

Stainless steel grade AISI 304, 2B milled finish :

SUTRONIC 3 Ra 0,7 p"m. e)
HOMMELTESTER P5D Ra 1.54 pm

Stainless steel polished to 22O GRIT :

SURTRONIC 3 Ra 0,15 p6 (2)
HOMMELTESTER P5D Ra 0.40 pm

Stainless steel electro polished:

SURTRONIC 3 Ra 0,13 pm. (2)
HOMMELTESTER PSD Ra 0.48 pm
 Page 3

Electron m hofsu
magnif ications

Material Evaluation (visual)

O Epoxy lining Smooth surface

O Stainless steel
- 2B Milled finish lrregular surface

a - 22O GRIT finish Serrated surface

O - Electro polish finish Smooth surface

ication
Polished surface

The polishing of stainless steel leaves a dark residual which is not eliminated
with standard pickling and passivating processes nor by standard brewing CIP
processes. EDAX analysis has detected presence of Al, Si, Cl, Ca, Ti, cr, and Fe
on samples taken from polished stainless steel vessels.

The composition of polishing materials contain:

Fe,Zn, Pb, S, C, Hg, Cu, Fe and leachable halogens: F, Br, l, Cl.

The surface of the vessels has to be tested by swabbing with cotton wool
dampened with surgical spirits or absolute alcohol, noting the discolouration
obtained after rubbing over a 300 x 300mm surface area. lf the cotton wool swab
is darker than colour reference chart-Cloud White (SABS 1091 Colour reference
G8O)3, the surface has to be recleaned.

Temporary protective coatings to avoid damage of the surface are commonly

useda. These can be, paper, polythene, polylthylene or p.v.c. The use of
polyethylene has shown to contaminate the stainless steel with a plasticiser
(phthalate) which covers the surface and renders pickting and passivating as well
as CIP useless to clean the metal surface. The plasticiser was detected using
infra - red analysis on the samples taken from fermenting vessels and from the
plastic (polyethylene) film used to cover stainless steel after polishing,

The use of paper to protect the steel surface is applied in the fabrication of rolled
stainless steel material. This paper, which leaves no contamination on the
stainless steel surface, is recommended, instead of any plastic protective coating.
 Page 4

CIP of process vessels

During the CIP of large (3-4000h1) fermenters it has been noted that polished
stainless steel vessels need a caustic and acid process in the cleaning
programme to eliminate allthe soil at the yeast ring. Epoxy lined tanks are clean
after only one acid process in the cleaning programme. This is partly attributed
to the "rougher" surface of stainless finish as shown by the surface
measurements (Ra) and electron-microscope photograph taken in this
investigation. The comparative results of the epoxy lined and electro polished
samples indicate that the surface profiles are similar, which offers an interesting
perspective and challenge to fabricators to obtain a surface which is cost
effective and ideal for the overall requirements of the brewing process.

The balance between costs of surface finish and C I P processes (detergents/

sterilants/time/temperature/energy/water/spray systems), needs to be life cycle
costed to ensure soil and biofilm build up are totally eliminated in the most cost
effective manner.
 Page 5

AC KNOWLEDG EM ENTS

O SAB Management permission to present data.

O A Derksen of SAB Central Laboratory. Electron Microscope

Photog raphs.

o J. Mc Allister of ECHALAZ & osBoRNE - Analytical service

O Columbus Stainless Steel - EDAX Analysis - Stainless Steel
Samples.

O De Beers Industrial Diamonds Research Laboratory - Surface

Measurement.

O University of Natal - lnfra Red Spectrum Analysis.

O BONMAC-Electro Polishing of Stainless Steel.

o BoBFAB - Plastic coating, stainless steel polishing and

Process Data.

o GEA Krugersdorp Engineering - Stainless Steel sampres.

O SAB Engineering and Projects Quality Assurance Department.

Quality Procedures and Surface Measurements.
 Page 6

R EFER E NC ES

1. Surtronic 3 operator's Handbook, Rank raylor Hobson, Leicester, England.

p 5-6.

2. Project Report VE. 85-OO1 of 23-04-1985 "Cleanabitity and Surface

Resistance Testing". South African Breweries, Conference Notes
(Unpublished).

"cleanliness of stainless steer vessets". south African Breweries,

Engineering Specification. EGS 004.

Surface Finishing Stainless Steel, lnformation Book No 1, Stainless Steel

Development Association, London. p47.

Hommel Tester PSD "operating instructions,'.

Hommel werke GMBH.

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