GCP Sect5NRB NRB Line

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GCP (NRB): Section 5 (NRB): Non-returnable bottling line
Institute of Brewing and Distilling

General Certificate in Beer Packaging
(GCP)
Section 5 NRB
Specialist Section – Non-returnable
Bottling Line.
5.NRB: A General Overview of Packaging Plant
A Packaging Line is designed to fill packages with beer and to present those
packages to the warehouse or customer suitably assembled in the most
efficient way while preserving the quality of the beer.
The design of the line will depend on the type of package and how it is
assembled, on the required rate or capacity of the line and on the type of beer
to be packaged.
The packaging line described below refers to:-
A non-returnable bottling line where new bottles are presented to the line
on pallets and the output is packed in cartons and assembled on pallets.
5.1 NRB Non-Returnable Bottling Line.
A flow diagram of an idealised Non-Returnable Bottling line is presented

below:
© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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NON RETURNABLE BOTTLING LINE FLOW DIAGRAM

Showing principal stages in the operation
Depalletiser
Rinser
Filler/Crowner
Sterile
Tunnel Beer
Pasteuriser
Labeller
Loose
Multi-packer Packaging
Carton Packer/
Tray Shrinkwrap
Palletiser
Warehouse
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Principal plant items.
De-palletiser.
Purpose Features Notes

To remove new Mechanical operation using Numerous moving parts and heavy
bottles from pallets pneumatic/hydraulic rams loading means that this machine needs
and to present them and electric motors. maintenance and attention.
to a conveyor for Sensing of positions by Work on the machine is potentially
transport the line. microswitches and light dangerous and safety interlocks/safe
beams systems of work are required.
Bottle Rinser.

To remove and A carousel, a conveyor The incoming bottles have been received
particles and dust from twist or an ‘S’ shaped from the manufacturer but may have been
inside the new bottles. belt where the bottles stored in a dusty warehouse, uncovered.
are inverted, jetted Rinse water from the jetter can be checked
with air then with clean for debris.
water.
Empty package inspection.

To check that the Inspection is either ‘manually’ The need for the bottler to
empty bottles from by eye or electronically. demonstrate due diligence in
the washer meet the Electronic bottle inspectors protecting the customer means that
requirements of:- throw a beam of light through inspection is essential.
• Internal the bottle vertically or Modern systems incorporate side wall
cleanliness. horizontally and reject bottles inspection, base inspection, neck
• Contain no foreign that display shadows or give inspection and residual liquid
objects. an abnormal light pattern. inspection.
• Are undamaged.
The diagrams below indicate accept/ reject criteria:
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Accept Reject
Accept Reject
Accept Reject
Bottle filler.

To transfer beer into the bottle Filling machines consist of a A detailed
achieving the following parameters:- rotating circular tank which houses description of how
• Filling to the specified volume of a number of filling heads. The the bottle filler
beer. bottles are filled as they travel works is given
• Protecting the quality of the beer around the system. below.
by avoiding air pickup and There are several stations on the
avoiding fobbing. filler that are designed to ensure
• Filling at the specified rate. that the bottles are filled meeting
the specified parameters.
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Crowner.

To seal the bottle so that:- The crowner consists of a hopper that The crowner is
• Beer cannot leak out. presents the crowns to the head positioned close to
• Air cannot get in. correctly aligned and a head that the filler so that the
• The bottle is tamper proof. crimps the crown onto the top of the opportunity for air to
• The bottle can be opened bottle. enter the space
easily when required for The degree of crimp is adjusted to above the beer is
consumption. give a tight seal without damaging the minimised.
bottle.
Pasteurizer.

To produce a microbiologically For details of pasteurization
stable beer. techniques see Section 3.
Full Bottle inspection.

To check that Inspection is either The need for the bottler to demonstrate due diligence
the full bottles ‘manually’ by eye in meeting the requirements of both the national
from the or electronically. taxation (Excise)* authority or Trading Standards*
filler/crowner Electronic bottle means that inspection is essential.
meet the inspectors throw a Often a coarse inspection will take place after filling
requirements beam of light or and a more accurate one after pasteurization.
of:- radiation through Inspection is backed up with accurate volume
• Filled with the the bottle at the measurement for individual packages. In the case of
right volume beer level. bottles this means emptying the contents into a
of beer. Incorrectly filled measuring cylinder.
• Are bottles are Records of inspection are kept for the relevant
undamaged. rejected. authorities.
Details of correct filling procedures are given in the
appropriate codes of practice.
* Or other national legislative and regulatory bodies.
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Labeller.

To put a label or labels onto Labelling machines comprise A labelling machine has many
the bottle that:- the following parts:- moving parts and needs to be
• Informs the customer • A magazine to hold stacks of carefully set up.
about the product giving labels. Points to take into consideration
details about name, • A glue system that transfers are bottle temperature and
alcohol content, volume, glue from a reservoir onto a dryness, label paper quality,
best before date etc. revolving drum which then glue consistency and
• Advertises the product by glues profiled palettes. temperature.
presenting an attractive • The revolving palettes to The glue migrates all over the
appearance when which the labels are machine and a cleaning regime
displayed. transferred face up. is required.
• Provides information for • A gripper cylinder which A diagram of a labelling
the manufacturer giving collects the glued labels and machine is shown in the
details about the code, transfers them to bottles. previous section on returnable
date, bottling line, bright • A revolving carousel that bottling
beer tank etc. holds the bottles so that the
glued labels can be attached.
Non-returnable bottles may also labelled with self-adhesive paper or plastic

labels or be screen printed (in which case paper labels would not be used).
Diagram of a wet glue applied, paper labeller:-
Labelling Machine
Glue
pallettes
Gripper
Labelling
cylinder
carousel
Label
Magazine
Glue roller
Labelled bottles Bottle feed to labeller
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Multipack Case packer.

To put full bottles into cardboard Mechanical operation Numerous moving parts means
boxes and to present them to a using pneumatic or that this machine needs
conveyor for transport to the mechanical grips for maintenance and attention.
palletiser. lifting the bottles into The machine is set up for one size
A ‘multipack’ is a single pack the boxes or forming of bottle and box.
containing a group of bottles the boxes around the Work on the machine is
that the customer buys as a unit bottles. dangerous and safety
Multipacks may be packed into Mechanism for closing interlocks/safe systems of work
‘Stock Holding Units’. the boxes. are required.
Carton erector/ packer.

To put full bottles into cardboard Mechanical operation Numerous moving parts means
boxes and to present them to a using pneumatic or that this machine needs
conveyor for transport to the mechanical grips for maintenance and attention.
palletiser. lifting the bottles into The machine is set up for one size
the boxes or forming of bottle and box.
the boxes around the Work on the machine is
bottles. dangerous and safety
Mechanism for closing interlocks/safe systems of work
the boxes. are required.
Shrink film.

To cover/surround packs in Mechanical operation Numerous moving parts means
plastic film to give added where a film is draped over that this machine needs
protection and to present the pack which is then maintenance and attention.
them to a conveyor for passed through a heated Work on the machine is dangerous
transport to the palletiser. tunnel where the film and safety interlocks/safe systems
shrinks tight over the pack. of work are required.
Palletiser.

To stack full packs Mechanical operation using Numerous moving parts and heavy
onto pallets so that pneumatic/hydraulic rams loading means that this machine needs
they are stable and and electric motors. maintenance and attention.
to present them to a Sensing of positions by Work on the machine is dangerous and
conveyor for microswitches and light safety interlocks/safe systems of work are
transport the beams. required.
warehouse. Pallets may be stretch
wrapped for extra stability.
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Conveyors.

To transport bootles Conveyors consist of Metal conveyors need lubrication to reduce
along the line. a chain of slats driven friction although cardboard must be kept
The simplest conveyors by an electric motor. dry.
run along straight lines, The slats may be Conveyor speed can be automatically
conveyors can be made of metal controlled to meet the requirements of the
designed to run around (stainless steel) or of a line. For example during a stoppage, the
shallow corners. plastic material. conveyor system can slow down or stop.
Conveying systems are designed with
automated speed control and line sensing
to provide dynamic accumulation between
all the principal line machines
Conveyors are designed to prevent bottles
from falling over.
Pallet inspection.

To check that the pallets from the de- Inspection is Pallets receive hard wear and
palletiser meet the requirements of :- usually ‘manually’ are often damaged.
• Fit for purpose. by eye. Stacking on damaged pallets is
• Are undamaged. hazardous.
Safety.
There are numerous hazards associated with bottling, these are itemised
below along with the normal procedures used to reduce or eliminate them:-
Hazard Safety procedure
Broken glass • Use of safety glasses.
• Guarding of plant.
Noise. • Plant design to reduce bottles colliding etc.
• Building design to adsorb noise.
• Use of ear protectors.
Hazardous gases. • Staff awareness of hazards.
Slips trips and falls. • Use of non slip materials for floors and steps etc.
• Regular cleaning of floors.
• Limited use of hoses.
Machinery accidents. • Permit to work procedures for maintenance.
• Guarding of machinery.
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5.2 NRB Bottle Filling Systems

Filling Principles for Beer into Bottles
There are a number of types of filler on the market. However, one principle
always applies, and that is carbonated beverages must be filled under
pressure in order to keep the gas (carbon dioxide and sometimes nitrogen) in
solution. Fillers employing this principal are called barometric or more
commonly counter-pressure fillers.
Previously, gravity fillers were used, but these do not give such a clean fill.
For beer, filling is more difficult than for other carbonated beverages because
of two unique qualities:
1. Head retention
2. The damaging effect of oxygen
For beer filling it is necessary to remove oxygen from the container before
filling. This is done by pre-evacuating a glass bottle or CO2 flushing a PET
bottle or can before filling. Pre-evacuation is carried out by applying a 90%
vacuum twice which will give a 99% pure CO2 gas in the bottle before filling.
Flushing with CO2, as is the case for PET and cans, will generally give a result
above 90% CO2 purity, but it will be lower than that achieved with the pre-
evacuation of glass bottles.
When filling beer into glass bottles, therefore, a pre-evacuation or flushing

facility will be required. It is also possible to limit oxygen uptake by using a
long tube rather than short tube filler.
With a long tube filler, the beer is filled from the bottom of the bottle and then
rises gently with only the top surface in contact with the gas space in the
bottle.
With a short tube filler, the beer flows down the outside of the tube, and it is
then deflected by a spreader rubber fitted to the tube. This directs the flow of
beer down the inside side-wall of the bottle. The whole of the surface area of
the beer flowing down the side of the bottle is therefore in contact with the gas
space during filling.
The following two diagrams illustrate the differences, and demonstrate how
the beer is exposed to the gas that it is displacing.
It can be seen that with the long tube filler only the top surface of the beer is
exposed so, as a result, the oxygen uptake is less than it is with a short tube
filler.
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Short Tube Long Tube
Short tube versus long tube
The long tube filler shown in this illustration shows the filling of a PET bottle.
This assists in reducing the uptake of oxygen because pre-evacuation is not
possible with PET.
The popular choice for bottle beer filling is a short tube filler with pre-
evacuation, and with double pre-evacuation good oxygen levels can be
achieved. Short tube fillers are easier to maintain and tubes and change parts
are cheaper. Waste will also be slightly lower as the tube will carry less beer
when it is withdrawn from the bottle.
Fillers can be mechanical or electro-pneumatic.

In the mechanical versions, the filling cycle is operated by trips and cams
which are located at set points around the circumference of the filler. The trips
turn the levers on the filling heads, and the cams operate the vacuum and
snift valves. So, in order for the filling cycle to complete, the filler must
continuously rotate. The fill level is controlled by the length of vent tube (short
tube) which returns the gas to the filler bowl. When the beer covers the end of
the tube it prevents the return of gas and therefore stops the filling operation.
With the electro-pneumatic version, the filling cycle is programmed for each
filling head. The filling cycle does not, therefore, depend on the rotation of the
filler for the cycle to operate. This is an advantage when the filler stops with
containers on it, as the filling cycle will continue to beer shut off.
On the mechanical filler, the beer valve can be open and one is dependent on
a perfect seal between the valve and container to prevent over-fill. The fill
level is sensed by a probe and this shuts off the supply of beer.
Fillers can also be volumetric. With these fillers the volume beer can be
metered via a magnetic flow (magflo) meter or alternatively each head is fitted
with a cylinder of a given volume. The volume released by the cylinder is
programmed via a float or conductivity probe.
A filler designed for volumetric filling does not need a ring bowl for beer, but
may well be fed from a constant pressure tank as controlled conditions are
required for an accurate and smooth operation.
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Bottle Filler Features

To transfer beer into the bottle Filling machines consist of a A detailed
achieving the following parameters:- rotating circular tank which houses description of how
• Filling to the specified volume of a number of filling heads. The the bottle filler
beer. bottles are filled as they travel works is given
• Protecting the quality of the beer around the system. below.
by avoiding air pickup and There are several stations on the
avoiding fobbing. filler that are designed to ensure
• Filling at the specified rate. that the bottles are filled meeting
the specified parameters.
The Filling Cycle for Counter-pressure Bottle Fillers
Different types of fillers have already been discussed. It is now understood,

therefore, that fillers used for beer are counter-pressure fillers and are
generally short tube. For glass bottle fillers the air is displaced by CO2 using
pre-evacuation. Vacuum (90%) is normally applied twice leaving 1% air in the
bottle.
The container is then pressurised until the pressure is equal to the pressure in
the filler bowl; on equalisation, the valve will open allowing the beer to flow
down the inner side of the container. As soon as the beer reaches the tip of
the vent valve the return gas passage will be blocked so allowing an
immediate pressure build up in the bottle which will, in turn, stop the beer
flowing.
Plan view of Bottle Filler
3. Filling
2. Counter pressure
4. Full
5. Snift 1. Evacuation
Full bottles to the Crowner Empty bottles in
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Bottles are fed onto the filler by a crown wheel which picks them up from the
conveyor, separates them and spaces them so that they fit onto the bottle lifts
which raise them up to seal on the filling head.
Beer is supplied from the Bright Beer Tank. The temperature of the beer for
packaging must be low (less than 3°C) to keep dissolved gasses in solution. It
may be necessary to install a trim chiller in the line.
The bottling machine has a circular beer tank whose level is automatically
controlled by supplying beer at the same rate as filling and venting off to
control top pressure. This venting also releases the air which accumulates in
the filler bowl when bottles are filled.
Beer Supply to the Bottling Machine

Vent CO2
Bright Bottling Machine

beer Level
tank
Control
Beer Supply Pump
Level control can be by float switch, electronic probe or by pressure control.
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Bottling machine operation:-
1. Evacuation
The bottles are full of air as they leave the washer, the purpose of the
evacuation stage is to remove as much of that air as possible.
Gas CO 2
Beer
Stage 1.
Evacuation
Bottle lift
The filling machine is fitted with a vacuum ring connected to a vacuum pump
which evacuates the bottle as shown in the diagram.
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2. Counter pressure.
The bottle is then counter pressured with CO2 , possibly from the gas space
above the beer in the filling machine’s beer reservoir as shown in the diagram
or from a separate source.
The purposes of counter pressurising the bottle before filling are:-
• To prevent the beer from fobbing during filling. A constant top pressure will
keep dissolved gasses (CO2) in solution.
• To provide an inert gas atmosphere in the bottle and avoid oxygen pickup.
Gas CO 2
Beer
Stage 2.
Counter pressure
Bottle lift
When the pressure in the bottle equals the top pressure above the beer, the
beer can fill the bottle gently by gravity alone.
In some filling machines, the bottle is evacuated, flushed with CO2 ,

re-evacuated and then countered pressured. This procedure is used when
there is a requirement for air removal to be even more effective.
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3. Filling.
Bottle filling has to achieve the following objectives:-
• The correct volume of beer must be put into the bottle. This is achieved
either by controlling the level to which the bottle is filled as shown in the
diagram or by filling the bottle from a volume controlled filling chamber.
• To protect the quality of the beer by preventing gas release through fobbing
and by the prevention of oxygen pickup. This is achieved by counter
pressuring and by filling as gently as possible so as not to disturb the beer.
A gentle fill is achieved by filling from the base of the bottle through a long
tube or by running the beer down the inside walls of the bottle as shown in
the diagram.
Gas CO 2 out
Beer
Fill height
Stage 3.
Beer in
Filling
Bottle lift
The beer valve opens to let the beer in while the gas in the bottle is released
into the head space above the beer in the filling bowl.
In most fillers, the beer valve opens against a spring when the pressure in the
bottle equals the pressure above the beer.
If the bottle bursts during filling, the pressure in the beer chamber closes the
beer valve immediately.
Procedures must be in place to ensure that broken glass from a burst bottle
does not migrate into other packages.
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4. Full.
The bottle is full when the beer level reaches and rises up the filling tube. With
this design of filler, tubes need to be changed for different sizes of bottle; a
tube change is not required with a volumetric filling system.
G as CO 2
B eer
S ta g e 4 .
F u ll
B o ttle lift
5. Snift.
A controlled ‘snift’ is introduced to release the top pressure gently.
G as CO 2
Beer
S ta g e 5 .
S n ift
B o ttle lift
The gas space above the beer in the bottle is pressurised and the beer will
fob if this pressure is released quickly when the bottle comes off the filling
machine.
Some machines give a double snift.
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As mentioned above, some filling machines fill the container with a measured
volume of beer. These are called a volumetric filling machines. The filling
principles are the same but a metering chamber is incorporated in the
system:-
CO2 supply
Beer level probe
Metering
chamber
Beer
supply
valve
The full bottle is now ready for crowning, though as it leaves the filling
machine, it is deliberately fobbed up to expel any air that may be present in
the head space. This fobbing is initiated by tapping, vibrating or, more usually,
by jetting a small volume of water (normally hot water) into the bottle.
The jetter is set so that the overflow is just taking place as the crown, or any
other closure, is placed on top of the bottle.
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5.3 NRB: Bottle Crowner

As it leaves the filling machine, the full bottle is ready for crowning and it is
deliberately fobbed up to expel any air that may be present in the head space.
This fobbing is initiated by tapping, vibrating or, most commonly, by jetting a
small volume of water into the bottle.
Crowner.

To seal the bottle so that:- The crowner consists of a hopper that The crowner is
• Beer cannot leak out. presents the crowns to the head positioned close to
• Air cannot get in. correctly aligned and a head that the filler so that the
• The bottle is tamper proof. crimps the crown onto the top of the opportunity for air to
• The bottle can be opened bottle. enter the space
easily when required for The degree of crimp is adjusted to above the beer is
consumption. give a tight seal without damaging the minimised.
bottle.
Crowning
The crown is still the most popular form of closure for beer. It is both capable
of holding the pressure in the container as well as venting gas safely when it
is removed prior to consumption. The crowning machine (often called the
‘crowner’) is blocked with the filler and runs in synchronisation with it.
The high level crowner hopper dispenses a crown down a chute, through a
tube which ensures the correct orientation of the crown, and onto the bottle.
The crowning head then applies a vertical load to the crown to ensure that the
sealing pad (insert) is compressed between the metal and the glass of the
bottle. While this load is maintained, a specially profiled hardened die is
forced down over the skirt of the crown creating the seal.
The finished diameter of the crown is critical with a tolerance of only 0.6mm
(28.7+/- 0.3mm).
Crowners should always be kept clean. Dust build up from the crowns can
congeal and effect performance as well as creating a contamination risk.
Some fillers have crowners with cleaning in place (CIP) installed. This makes
the cleaning operation much more complete.
Crown tolerance is measured using a ‘Go No Go’ gauge. This could be a 3
hole gauge with hole sizes of 28.4mm, 28.7mm and 29.0mm.
A Go No Go gauge
28.4mm 28.7mm 29.0mm
It should be difficult to pass the 28.4mm gauge over the crown. If it slips over
the crown, it is too tight and this could lead to bottle breakage when the crown
is removed. If the 29.0mm gauge does not go over the crown, it is too loose
and this will give leakages. A full set of bottles off the crowner should be
checked each shift and after a changeover.
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C ro w n co rk clo su re
se a l
Bottle Crowns
The most commonly used crown liners today are PVC and PVC-Free Dry-
blends.
They are suitable for good pressure retention before and after pasteurization,
stacking, oxygen barrier and scavenging with soft and hard polymers. A
double lip design is used.
Pry off crowns are used on bottles with a standard finish.

However, a twist off crown needs to be profiled to fit the bottle threaded neck
finish. The same crowning machine can be used but the crown tolerances
need to be better managed within the standard tolerance of 28.7mm+/-0.3mm.
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5.4 Sterile Filling

Summary
Many packaging operations use sterile filling procedures for bottles and cans
to avoid the need for tunnel pasteurization.
Sterile filling is a term used for filling when it is important to ensure that there
is no pick up of infection during filling. This would apply when beer is filled
after being flash pasteurized or sterile filtered.
Several modifications to standard filling procedures will be necessary to

achieve the higher level of sanitised conditions required, but generally a
modern standard filler can be used for this type of filling, especially if they are
easy to clean. Usually a much more rigourous and disciplined cleaning regime
is necessary to ensure good product stability.
In addition, the filler may be placed in a guarded area which is kept clean, so
that the filler is enclosed in a microbe free environment. This could mean a
separate room or a “shroud” over the filler, either of which is fitted with a
sterile air filter and the air is changed frequently and kept at a slight positive
pressure to ensure no ingress of dirty air.
The immediate working area around the filler (either the sterile room or
shroud) should be regarded as a “sterile envelope” and is likely to have
sterilant sprays fitted in order to drench the whole filler with sterilant (such as
chlorine dioxide) after operators or engineers have had to approach the filler
for whatever reason, so that the sterile integrity is not compromised.
Only operators and engineers equipped with appropriate protective clothing

should be permitted to enter the “sterile envelope”.
Sterile Filling – Operating Details
Sterile filling is more achievable today as standard machines are designed to

be hygienic and are much easier to clean.
The main differences in approach on a line without an in-package (or tunnel)
pasteurizer are:
The beer to be packaged must be sterile i.e. completely clear of all beer
spoilage organisms
The filler installation and layout must be hygienic
The environment around the filler must be free of any organisms which
could infect the beer
The bottles and closures need to be sterile
Cleaning and CIP regimes need to be totally disciplined
The training of personnel in hygiene and methods of operation need to be
carried out to ensure total understanding and commitment
Micro back up from the laboratory is essential
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Beer sterilization
The beer can be sterilized in two ways:

Sterile filtration
Plate (or Flash) Pasteurization
Each type has its benefits. Sterile filtration will produce beer that has no heat
damage, and can be installed in-line to the filler making the operation much
simpler. However, the process needs to be closely monitored and filters need
to be well maintained. The method chosen today is usually plate
pasteurization as it is easier and cheaper to manage; also there does not
appear to be any detectable heat damage for the discerning beer taster!
For comparison purposes, the capital cost for the installation of a sterile filter
would be about 50% higher and running costs approximately 3 times greater.
With a plate pasteurizer, however, a sterile buffer tank needs to be installed in
order to balance the system. This is because a plate pasteurizer cannot give
an instantaneous change in supply as the filler slows down, speeds up and
stops!
Another advantage is that with a plate pasteurizer bottles and cans can be
packaged at a higher temperature (which can go up to 15oC), depending on
the gas content. This can be important with regard to keeping finished packs
free of condensation.
Also, for bottle labelling, the bottle needs to be condensate free (dry surface).
Beer from a sterile filter will be around 4oC when bottled, so a bottle warmer
may be required to warm up the bottles before the labels are applied.
Filler Installation and Layout
Good design practices must be followed from the exit of the pasteurizer or
sterile filter right up to the filler. This will include:
No CIP dead legs. Points where the solution will not pass when being
circulated
Valves or caps on T’s less than 1.5 pipe diameters away from the junction
CIP flow rates designed to give high levels of turbulence (velocities > 2m/s
ideally 2.5 m/s)
Use of hygienic fittings and valves
Make pipe runs as short as possible
Do not create traps – all pipe work should be able to self-drain
All gas in contact with the beer is sterile – filtering with a 0.25 micron filter
should be sufficient, and as close to the point of use as possible. Simple
cleaning facility (steam) and easy filter replacement must be considered
In the case of the Sterile Buffer Tank all fittings, including temperature and
level probes, need to be flushed along with the internal surface of the vessel.
The sample cock needs to be a membrane type. Ensure that the programmes
for CIP, flushing, beer intake, changeovers and finish have been precisely
specified to ensure no contamination.
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The bottle rinser must be blocked with filler to ensure a short, synchronised
transfer from the rinser to the filler. With a can filler this is not possible so extra
care must taken in the transfer of the cans from the rinser to the filler.
Filler Environment
The environment around the filling area must be hygienically clean. There are
two lines of thought on this:
1. Make sure that the packaging hall, and especially the area around the filler,
are easy to clean, and can be seen as visibly clean – light coloured tiled
floors and walls are best. The hall should be fed with filtered air.
2. As an extra precaution the filler is enclosed with a gap at the bottom to
allow proper cleaning of the floor. The enclosure is fed with filtered air and
a positive pressure is maintained inside the area.
The important thing is to not allow the enclosure to give a false sense of
security. The internal area must be kept clean and the air filters properly
maintained. Any breakages and beer must be quickly washed away with sterile
water and the same strict cleaning regime kept in place.
Sterility of Bottles, Cans and Closures
Bottles can either be returnable or non-returnable. Returnable bottles will

have been treated at a high temperature, and so long as they are shiny clean,
they should be infection-free. However, all this good work can be spoilt if the
final rinse water is contaminated. It is normal therefore to treat the water with
a low level of chlorine 2 to 3ppm, to ensure sterility. Many brewers will not
allow chlorine to be used due the danger of chlorophenol (like TCP) being
formed in the beer should it come in contact with the residual chlorine.
As a result chlorine dioxide at 0.25 to 0.5 ppm or PAA (Peracetic Acid) at 150
to 250 ppm is more commonly used.
For new bottles the same applies – the water, as an extra precaution, could
be passed through a 0.45 micron filter (or less), or be UV (Ultra Violet)
treated. It is also possible to use steam rinsers or rinse bottles with sterile air.
Steam would not be suitable for PET bottles. Chemical treatment with
Chlorine Dioxide or PAA is advised as this treatment is residual. (Remains in
contact with the surface).
It is now a common approach to deliver a sterile bottle to the filler. It is also
possible to purchase a sterile filler which actually steam sterilizes the bottle
before filling, as part of the filling cycle. The downside is that the bottle
breakage increases as the bottle is still hot when the cold beer meets the
glass
Crowns or caps can be sprayed with 300ppm PAA (Peracetic Acid ) or be

treated with UV. However, general advice is to keep them dry in a clean
storage area. Dry crowns will not carry infection.
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For Cans, the same principles apply for rinsing. However, cans are not
breakable so can be steam sterilized.
A filler can be purchased which sterilizes the can with steam as part of the
filling cycle.
Ends can be UV sterilized before seaming, however if they are kept dry UV
treatment may not be necessary. Sprays, as used with crowns, are not easy
to apply during end transfer.
Cleaning and CIP
There is no correct way – the important thing is that it is effective in preventing

infection and this will be discovered through trials. For sterile filling, there will
be a need for more cleaning time and this will affect the utilization of the line.
With sterile filling, it is good practice to run the containers out of the filler every
two hours, and then hose down the filler externally with water which has been
treated with PAA or chlorine dioxide. This could take 5-10 minutes which is
equivalent to a 4 to 8% loss of utilization. A full CIP, or internal cleaning;
needs to happen at least twice a week when continuous running. It should
also take place after stops, or at beer changes. The CIP will consist of a rinse,
caustic wash, another rinse, and then finally a rinse with PAA or chlorine
dioxide treated water. External foam cleaning needs to take place after CIP.
Training of Personnel
No person should be allowed near the filler without the proper training in
hygiene and operation. It is important that an assessment of each individual is
carried out after training, and that only certified people are allowed to operate
or maintain the plant. A certain amount of classroom training in hygiene and
operation must be given to the operators and engineers first. It is also
important that proper, simple and straight forward work instructions with
diagrams are prepared for the operation, so as there is no misunderstanding
about what needs to be done. The implications of not carrying out instructions
must be clearly understood.
Microbiological Back Up
So as to ensure that a sterile product is not going to be contaminated, it is

important that all points of contact such as mains, valves, pumps and vessels
are absolutely clean and infection free. A good discipline must be in place for
sampling especially as there is a delay of 4 to 7 days before it is known
whether a product sample is free of infection. Sampling regimes must also be
traceable.
A summary of some good practices are:
An adequate sampling room which allows at least two samples from each
batch to be kept for the given shelf life for the product.
An extra one to two samples to be passed through a membrane filter and
incubated anaerobically for 4-7 days and aerobically for 2-4 days.
24
Two samples to be taken for forcing tests and kept in warm storage (25-
30oC) for a period of 4-6 weeks.
Continuous samples are collected from the line feed to the filler every 2
hours from a continuous membrane sampler.
Swabs are taken from plant after cleaning for bioluminescence testing to
ensure cleanliness.
Tests carried out on the water supply, water from the rinser, water from the
tanks and filler after cleaning. Also checks on gas supplies used CO2
(perhaps N2) and crowns. Indeed anything that will come into contact with
the beer.

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1

GCP (NRB): Section 5 (NRB): Non-returnable bottling line

Institute of Brewing and Distilling

The packaging line described below refers to:-

5.1 NRB Non-Returnable Bottling Line.

A flow diagram of an idealised Non-Returnable Bottling line is presented

NON RETURNABLE BOTTLING LINE FLOW DIAGRAM

Principal plant items.

Purpose Features Notes

Purpose Features Notes

Empty package inspection.

Purpose Features Notes

The diagrams below indicate accept/ reject criteria:

Purpose Features Notes

Purpose Features Notes

Purpose Features Notes

Full Bottle inspection.

Purpose Features Notes

* Or other national legislative and regulatory bodies.

Purpose Features Notes

Non-returnable bottles may also labelled with self-adhesive paper or plastic

Diagram of a wet glue applied, paper labeller:-

Labelled bottles Bottle feed to labeller

Multipack Case packer.

Purpose Features Notes

Carton erector/ packer.

Purpose Features Notes

Purpose Features Notes

Purpose Features Notes

Purpose Features Notes

Purpose Features Notes

5.2 NRB Bottle Filling Systems

When filling beer into glass bottles, therefore, a pre-evacuation or flushing

Short Tube Long Tube

Short tube versus long tube

Fillers can be mechanical or electro-pneumatic.

Bottle Filler Features

Purpose Features Notes

The Filling Cycle for Counter-pressure Bottle Fillers

Different types of fillers have already been discussed. It is now understood,

Plan view of Bottle Filler

Full bottles to the Crowner Empty bottles in

Beer Supply to the Bottling Machine

Bright Bottling Machine

Beer Supply Pump

Level control can be by float switch, electronic probe or by pressure control.

Bottling machine operation:-

In some filling machines, the bottle is evacuated, flushed with CO2 ,

Bottle filling has to achieve the following objectives:-

5.3 NRB: Bottle Crowner

Purpose Features Notes

Pry off crowns are used on bottles with a standard finish.

5.4 Sterile Filling

Several modifications to standard filling procedures will be necessary to

Only operators and engineers equipped with appropriate protective clothing

Sterile Filling – Operating Details

Sterile filling is more achievable today as standard machines are designed to

The beer can be sterilized in two ways:

Filler Installation and Layout

Sterility of Bottles, Cans and Closures

Bottles can either be returnable or non-returnable. Returnable bottles will

Crowns or caps can be sprayed with 300ppm PAA (Peracetic Acid ) or be

Cleaning and CIP

There is no correct way – the important thing is that it is effective in preventing