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GCP (All Containers): Section 19: Utilities – Process Gases

Institute of Brewing and Distilling

General Certificate in Beer Packaging
(GCP)
Section 19 Utilities - Process Gases.
19.1 Properties, Applications and Safety of Gases.

Requirements.
Candidates should be familiar with common practices aimed at ensuring economy of
use and purity of supply of Process Gases.
Familiarity with safety features of the supply systems is also required.

The Brewery needs inert gases to protect the beer’s quality. All these utilities are
potential safety hazards and procedures must be in place to protect the people who
work in the plant.
The main uses of Gases in Brewing and Packaging

Gas Purpose Method of use

Air or To ensure yeast growth. • Injection into wort during chilling.
oxygen. • Aeration of yeast cultures or
yeast during storage.
Air. To drive pneumatic equipment. Pipework direct to plant
Nitrogen. • To enhance beer’s foam • By injecting N2 into the beer,
stability. usually during the packaging
process.
• By pressurising the package with
N2.
• To replace air in tanks and • Flooding tanks and packages
packages creating an inert with N2.
atmosphere.
• De-gassing beer that has a • Purging from the base or outlet of
high level of dissolved a tank.
oxygen or carbon dioxide.
Carbon • To give beer its fizzy • Injection into beer.
dioxide. character.
• To replace air in tanks and • Flooding tanks and packages
packages creating an inert with CO2.
atmosphere.
• To act as an oxygen • Filling de-aeration tower with
scavenge in de-aeration CO2.
plants.
• De-gassing beer. • Purging from the base or outlet of
a tank.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 19: Utilities – Process Gases

The Quality of Gases in relation to their use

Gas and its Quality parameter Reason

use
Air or oxygen • Sterility. • Product will become infected.
for yeast
growth. • Freedom from • Contamination.
contaminants e.g. oil or
grease.
Air for Dry and clean. Inoperation of equipment.
pneumatic
plant.
Nitrogen for • Purity, especially absence • Even a small amount of oxygen
foam stability of oxygen. will cause flavour staling and beer
or air instability.
elimination.
• Sterility. • Product will become infected.

• Freedom from • Contamination.

contaminants e.g. oil or
grease.
Carbon • Purity, especially absence • Even a small amount of oxygen
dioxide for of oxygen. will cause flavour staling and beer
beer instability.
condition or
air • Sterility. • Product will become infected.
elimination. • Freedom from • Contamination.
contaminants e.g. oil or
grease.

Gases are sterilised by filtration through very fine filters which have to be steam
sterilised.

Carbon dioxide, especially that collected from fermentations, is checked for purity,
cleaned and dried as necessary. Only pure CO2 must be re-used.

The collection of, purchase of and the production of these gases is expensive.
Wastage is a problem because the gas distribution systems are under high pressure
and leaks are common.

The detection of and repair of gas leaks are important areas in cost control.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 19: Utilities – Process Gases

19.2 Health and Safety.

Carbon dioxide is a safety hazard especially in fermenting rooms. There are several
features of this gas to be considered:
• It is a toxic gas at high concentrations in the atmosphere.
5% of CO2 in the atmosphere is dangerous.
• It is heavier than air and it will accumulate in low-lying areas.
• It is generated in very large quantities during fermentation.

The risks associated with CO2 can be reduced by:

• Effective removal of the gas from FV rooms using extraction systems.
• CO2 collection from fermentations.
• The installation of gas detectors. Alarms indicate levels above 0.5%
• Safety measures that include permits to work, permits to enter confined spaces
and evacuation procedures.

Nitrogen is potentially dangerous because it will suffocate and it is difficult to detect

(air is 80% N2). People required to enter tanks where N2 is used for back pressure
are especially at risk.
Dangers can be reduced by the installation of gas detectors (Oxygen deficiency
meters).

All pressurised process gas systems (including compressed air) present safety
hazards. If pressure systems fail, they can seriously kill or injure people. Most
countries have regulations dealing with the risks created by a release of stored
energy should the system fail and detailing the measures that should be taken to
prevent failures and reduce risks. The regulations generally cover:
• Safe operating limits.
• Written schemes of examination.
• Specific requirements relating to most pressure vessels, all safety devices and
any pipework which is potentially dangerous.

Compressed gas cylinders can present severe hazards to personnel and property.
Many gas cylinders are stored at extremely high pressure. A sudden release of gas
can cause a cylinder to become a missile-like projectile of fracture catastrophically.
There are well recognised procedures to minimise risks covering:
• Labelling
• Handling
• Storage
• Transporting
• Use of personal protective equipment.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (All Containers): Section 19: Utilities – Process Gases

Notes:

Candidates should familiarise themselves with their own brewery’s procedures for:

• the safe entry into tanks, cold rooms and other confined spaces where carbon
dioxide or excessive nitrogen may be present

• the use of portable and fixed alarms together with other personal protective
equipment

Candidates should also investigate their own national (and any local) safety
regulations and procedures relating to:

• the storage of liquid gases and their distribution in high-pressure mains

• compressed air systems and equipment

• the safe handling and storage of compressed gas cylinders

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