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GCP (All Containers): Section 10: Warehousing

Institute of Brewing and Distilling

General Certificate in Beer Packaging
(GCP)
Section 10
Warehousing.
10.1 Warehouse Operations and Practices

Warehousing relates to the storage and dispatch of beer, and the reception
storage and issue of packaging materials.

Ideally, packaged beer would be delivered to customers directly from the

packaging lines. The exact matching of packaging runs to the customers’
requirements, however is not possible and a buffer store of product ready for
sale is essential.

Warehousing is an expensive operation, it requires large areas of space and

the multi handling of packages or pallets.
Space can be used more efficiently if units/pallets are stacked one on top of
another. This can be done on racks or by stacking robust pallets, for example
pallets of containers. The height that stacks can go depends on the stability of
the unit being stacked and the use of mechanical stacking equipment.

Space utilisation is a balance between filling the available volume and

keeping products separate for ease of stock management.

The number of times that a unit is handled before being dispatched affects the
costs of the warehousing operation. Obviously, the fewer times the better and
it is normal to use computer systems to handle stock control especially when
a large number of items is being stored.

Best Practices

There are a number of rules governing the warehousing of beer to ensure that
maximum quality, customer satisfaction and legal obligations are met:-

• Stock rotation must be on a ‘first in first out’ basis. The age of beer in
package is a key quality parameter and as a general rule, the younger the
better. Some breweries operate a ‘positive release’ system that ensures
that only beer that meets specification is despatched to customers.
• Storage conditions must reflect the product being stored:-

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 10: Warehousing

Temperature.
The temperature range for filtered beer storage is quite wide: it must be
above freezing and should be no higher than 25°C. Very low temperatures
could cause the beer to go hazy and very high temperatures could encourage
the development of infection or off flavours.

The required temperature range for cask conditioned beers is narrower

because yeast is present and beer conditioning needs to occur under optimal
conditions.
The ideal range is 10 - 17°C.
Condensation problems will affect stretch wrapped pallets if the bottles or
cans are still warm off the pasteuriser when they are wrapped and then
transferred into a cold warehouse.

Humidity.
Air humidity needs to be low because condensation on beer packages can
destroy the cardboard of trays and boxes etc.
Wet conditions will also adversely affect packaging materials like cardboard.

Handling.
Beer packages need to be handled with care, cans for example are easily
damaged.

Housekeeping.

Pests, for example pigeons, mice and cockroaches are attracted to

warehouses, especially if they are not kept clean and tidy. A hygiene
procedure needs to be in place to eliminate all types of pests.

[ For hygiene procedures for floors and walls, see Section 17. ]

Stock taking and control are much easier and more effective in tidy conditions.

Stock control and Taxation (Excise) regulations.

Beer in package is liable for duty although the duty is usually paid when the
beer leaves the site (i.e. at the gate).Product traceability is a prerequisite.
Taxation (Excise) regulations demand that detailed records are kept so that
the correct duty is paid.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 10: Warehousing

10.2 Health and Safety.

There are numerous hazards associated with warehousing and distribution,
these are itemised below along with the normal procedures used to reduce or
eliminate them:-

Hazard Safety procedure

Manual handling • Plant and systems designed for minimum manual handling.
accidents • Staff training in safe working procedures.
• Use of hard hats and safety wear.
Fork Lift Truck and • Separation of FLTs and all vehicles from pedestrians; use of
other vehicle clearly marked walkways.
accidents • Audible and visible alarms.
• Staff training in safe working procedures, for example pre-use
checks on FLTs.
• Use of high visibility clothing.
Slips trips and • Use of non slip materials for floors and steps etc.
falls. • Regular cleaning of floors.
• Limited use of hoses.
Machinery • Permit to work procedures for maintenance.
accidents. • Guarding of machinery.

Notes.

Describe the warehousing operation at your brewery.

What checks, other than for stock control, are carried out in this warehouse?

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)