GCP Sect18 Water and Effluent

1
GCP (All Containers): Section 18: Utilities – Water and Effluent in packaging
Institute of Brewing and Distilling

General Certificate in Beer Packaging
(GCP)
Section 18
Utilities - Water and Effluent in
Packaging.
18.1 Water Treatments.
A plentiful supply of water is essential to the brewery; this is why, in the past,
breweries were built in areas that had their own sources, usually in the form of
wells or boreholes. These original sources are still used in some plants while
others have to rely on the local water authority for their supply.
The nature of the water source will affect the quality of the beer and this has
resulted in some areas being famous for their beers. Examples are Burton-
on-Trent for strong bitters and Pilsen for fine lagers. The quality of the water
will also affect the efficiency of the processes where it is used, for example in
boiler feed water or in plant cleaning systems.
Water can be sourced from underground wells (boreholes) or from a surface
supply like a reservoir.
Borehole Water: Surface Water:
Rain Bore hole
Top soil
Rain
Sub soil
Reservoir
Water bearing rock
Impervious rock
The Principal Characteristics and Requirements of a Brewery Water

Supply.
The source of supply will affect the characteristics of the water in the following
ways:
© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
2
Source Mineral Salt Microbiological Taints

Consistency of
Content Content Supply
Boreholes. Will contain some Likely to be low
Likely to be Very good over
of the soluble because the water
low unless long periods of
material present has been filtered
the water time.
in the rock strata through the rock
has been
where the water strata. contaminate
is held. d by surface
water, for
example in
built up
areas.
Surface Likely to be low Likely to be high Likely to be Can be variable
Water. unless because of low unless especially in
agricultural contamination the water is periods of
chemicals are from farm land. contaminate drought.
being washed off d by
the land. accidental
spillage.
Public Depends on Likely to be low Likely to be Very good

Supply. whether the because of low because because of the
source is treatment by the of treatment water authority’s
borehole or water authority. by the water legal
surface. Any authority. obligations.
anomalies should
be known if the
supplies
alternate.
A Brewery Water Supply should have the following characteristics:
Characteristic Standard
Appearance. Clear and colourless.
Wholesomeness/Potability. Freedom from taint.
Mineral salt and Metallic Contents that meet the brewing and process
content. requirements.
Microbiological standard. Freedom from any micro-organisms that would spoil
the beer or affect the people that drink it.
Reliability of supply. There must be water available at all times.
3
Water used in a Brewery can be identified as:

• Product (Brewing) Water – actually used in the production of beer.
• Process Water – used for cleaning plant, washing containers before filling.
• Service Water – used to raise steam (in Boilers), in refrigerants for cooling
(including cooling towers) and general hygiene.
Methods for Pre-treatment of Water.
Some water sources require no treatment at all, so the selection of a ‘perfect’

supply is the ideal; however a water supply that meets all requirements is rare
and usually some form of water treatment is used.
Quality Standard Treatment

Clear and colourless Filtration, usually sand filtration or by flocculation.
appearance.
Wholesomeness/potability - Filtration, usually by carbon filtration.
Freedom from taint.
Mineral salt and Metallic Carbonate removal by boiling, or more usually by
content that meets the brewing de-ionisation. Where the required salts are
and process requirements. absent, these can be added to the water tank or
during the process. For example, calcium chloride
can be added to the brewing process.
Freedom from any micro- Sterilisation by UV light, by sterile filtration, by
organisms that would spoil the pasteurisation or by the addition of a sanitiser.
beer or affect the people that
drink it.
There must be water available An alternative supply is often used. Where this is
at all times. the case, different water treatment may be
needed.
De-ionisation (removal of the salts) in Ion exchange columns is common in

breweries. The columns contain special resins that are capable of exchanging
the unwanted ions for harmless ones. The resins can be regenerated when
exhausted, usually by washing through with mineral acids.
In the plant illustrated below, Carbonates are removed in ion exchange

columns and CO2 is formed. This is removed in the degassing towers.
4
Acid regeneration tank
De-
Ion Gassing
Exchange Tower
Break Column
Tank
Alternative primary treatments are:
• Sand filtration for the removal of solids.
• Carbon filtration for the removal of flavour taints like chlorine.
• Ion exchange columns for de-mineralisation or de-alkalisation.
• Membrane filters or reverse osmosis. Reverse osmosis is a process where

water is passed via a high pressure pump through a semi-permeable
membrane which allows the passage of water but not the dissolved solids
in the water, which are concentrated and directed to the drain. With the
appropriate selection of membrane, water can be totally de-mineralised
and have bacteria, trihalomethanes (THM's), some pesticides, solvents and
other volatile organic compounds (VOC's) removed.
• Removal of iron or manganese using a BIRM filter.
De-aerated Water.
It is common to brew beer at ‘high gravity’ and to dilute the beer to its
specified alcohol content at a later stage, for example post filtration.
The water used for dilution has specific quality requirements ie
‘The water must be free of unwanted micro-organisms and the water must be
free of any dissolved oxygen’.
The de-aerated water plant is designed to supply water to that standard:
5
P re - tre a te d
W a te r
De-aeration
Column
F in e U .V .
C o a rs e C o o le r
F ilte r S te rilis e r
F ilte r
D e -a e ra te d
W a te r S u p p ly
Tank
The plant illustrated has the following features:

• A filtration system that ensures that the Ultra Violet (UV) light steriliser is
effective.
• A de-aeration system that works by spraying the water through an
atmosphere of inert gas (carbon dioxide or nitrogen) where any oxygen in
the water is replaced by the inert gas.
• Sterilisation by UV light (chlorine sterilisation would taint the water).
• Temperature adjustment (the water will eventually be added to beer at low
temperature).
Other plants remove oxygen by heating the water. Some sterilise the water
using heat or by membrane filtration.
Notes:
Describe how the de-aerated water plant operates in your brewery. Use flow
diagrams to illustrate your description.
Methods for Sterilising Water.
The method of water sterilisation depends on the level of infection and on the
subsequent use of the water. If the water is heavily infected it may require
filtration followed by heat treatment.
If the water is to be used for normal brewhouse operations sterilisation can be
by the addition of a sanitiser like chlorine gas, hypochlorite or chlorine dioxide.
If the water is to be used for addition to beer at later stages, for example the
dilution of high gravity beer and it is considered that chlorine would taint the
beer, then sterilisation by UV light or by sterile filtration is more usual.
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18.2. De-aerated, Process and Service Waters and Water

Conservation.
De-aerated Water.
De-aerated water is that water used for:
• Additions make up.

• Beer dilution to sales gravity.
• Jetting.
Water Use Quality Requirements Treatment

Additions makeup in The water must be free of See the section on water
Fermentation & unwanted micro-organisms. sterilisation.
Maturation. For later stages, the water See the section on water
The water used to mix must be free of any de-aeration.
and add material like dissolved oxygen.
finings.
Additions makeup in The water must be free of See the section on water
Filtration. unwanted micro-organisms. sterilisation.
The water used to mix The water must be free of See the section on water
and add filter aid. any dissolved oxygen. de-aeration.
Breakdown in Filtration. The water must be free of See the section on water
The water used to unwanted micro-organisms. sterilisation.
adjust alcohol content in The water must be free of See the section on water
high gravity beers. any dissolved oxygen. de-aeration.
Jetting in Packaging. The water must be free of See the section on water
The water used to jet unwanted micro-organisms. sterilisation.
into bottles to promote a The water must be free of See the section on water
CO2 purge. any dissolved oxygen. de-aeration.
Process Water.
Process water is that water used for:
• Cleaning brewery plant.

• Washing beer packages before filling.
• Heating, for example in tunnel pasteurisers.
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Water Use Problems Treatment

Cleaning Formation of scale in CIP Carbonate removal as described
brewery plant delivery systems and spray above.
(CIP). heads caused by the presence Selection of a detergent that works
of carbonates in the water. best with the water in use.
Detergent deterioration caused
by the presence of carbonates.
Bottle washing Formation of scale in the Washer Carbonate removal as described
Cask washing sprays and ‘bloom’ on bottles. above.
Keg washing. Detergent deterioration, all Selection of a detergent that works
caused by the presence of best with the water in use.
carbonates.
Rinsing plant Re-infection of the product or Water sterilisation as described
and packages plant through the presence of above.
after cleaning. micro-organisms.
Tunnel Formation of scale in the Carbonate removal as described
Pasteurisers. pasteuriser sprays caused by the above.
presence of carbonates. Use of additives that suppress
Formation of mould in the mould.
pasteuriser caused by the Use of additives that inhibit rust
presence of micro-organisms. formation.
Rust on the bottle crowns
caused by the activity of the
water.
Notes:
Describe the problems experienced with your brewery’s Process Water and
how these are overcome.
Service Water.
Service water is that water used in boilers to raise steam, in cooling towers as
part of the refrigeration plant and general hygiene cleaning.
Boiler Water:
The main requirements for boiler water are that it does not form scale
deposits on the heating surfaces and that it does not corrode the plant.
Consequently, the removal of carbonates is essential and often the standard
de-ionisation process described above is supplemented with further
treatment.
To prevent corrosion, additives are used to scavenge oxygen from the water
and its pH is adjusted.
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Cooling Tower Water:
Water used in cooling towers is prone to the growth of bacteria of which the
most important is Legionella.
Legionnaire’s disease is a potentially fatal pneumonia caused by legionella
bacteria. The infection is caused by breathing in small droplets of water
contaminated by the bacteria. The disease cannot be passed from one
person to another.
Legionella bacteria are common in natural water courses such as rivers and
ponds. Since legionella are widespread in the environment, they may
contaminate and grow in other water systems such as cooling towers,
evaporative condensers and hot and cold water services. They survive low
temperatures and thrive at temperatures between 20oC – 40oC if the
conditions are right, eg if a supply of nutrients is present such as rust, sludge,
scale, algae and other bacteria. They are killed by high temperatures.
In many countries there are regulations for managing the risks from
legionella. These regulations generally include:
• The identification and assessment of sources of risk;
• The preparation and management of a scheme to prevent or control
the risk;
• The keeping of records to check that what has been done is effective.
Cooling towers and similar systems are often treated using biocides but other
treatments are available such as UV irradiation, copper / silver ionisation and
ozone.
In hot and cold water systems legionella has traditionally been controlled by
storing water above 60oC and distributing it above 50oC - and cold water
below 20oC if possible. Other methods which are used include copper / silver
ionisation and chlorine dioxide treatment.
General Cleaning Water:
This is water that is used for hosing down and general hygiene and the
normal standard supply can be used.
Notes:
Describe the treatment used for your brewery’s boiler water and cooling tower
water.
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Water usage Ratios, Conservation Methods and Costs.
Water is an expensive commodity, it is charged for by the Water Authority

whether or not it comes from the brewery’s own boreholes and the brewery is
charged for any liquid sent down the drain. Consequently, a knowledge of
how much water is used is essential for its control.
Usage Ratios:
Breweries calculate the amount of water used compared to the amount of
beer produced. Surveys of breweries have shown that the ratio of volumes of
water consumption to production varies from 3:1 to 20:1. The adjudged
minimum ratio of consumption, allowing for unavoidable losses, is
approximately 1.4:1. In practice the minimum consumption is generally in the
range 2.5:1 to 5:1 depending on the operations carried out by the particular
brewery. The ratio is normally measured in hectolitre / hectolitre (hl/hl).
Notes:
Describe below, what your brewery’s water ratio is and what steps are taken
to reduce it.
18.3 Sources of Effluent and Measurement.
Effluent is the waste material discharged to the brewery drains. It is expensive

to process and the brewery is charged for this processing. The local authority
will also impose limits to the amount of and content of the effluent that the
brewery is allowed to discharge.
Sources in Brewing and Packaging operations
CO 2
W a re h o u se
B o ile r h o u s e P a c k a g in g H a ll
CO2
B o t tle a n d K e g
r in s e s
B re w h o u s e F e r m e n ta tio n F iltr a tio n
S p e n t g r a in d r a in in g s W a s te y e a s t &
W a s te F ilte r A id
a n d tr u b V e s s e l r in s e s
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Packaging Effluent
Effluent from the Packaging Hall comes from the washing of returnable
bottles, cask and keg washing machines, from filling machines and from
pasteurisers. In addition, some effluent is generated from bright beer vessel
and pipework cleaning operations.
Package washing is the most likely cause of effluent problems; detergents are
used and the packages have to be rinsed with fresh water before being filled.
Returnable bottle washing machines are required to remove paper labels
which could be washed to drain.
Many tunnel pasteurisers use large volumes of water, some of which is
carried over with the packages on the exit conveyor.
Effluent Values
Effluent is measured in five ways - Volume, Suspended Solids, COD, pH and
temperature. A brewery can often be charged by the Water Authority using a
formula (such as the Mogden formula) incorporating a number of the key
values. The formula is adjusted to comply with local needs.
The values are explained in the table below:
Value Explanation Source

Volume The volume of effluent discharged, usually Wastage of water
measured in cubic metres. described above.
Suspended The amount of solid material in the effluent, Spent grain, trub,
Solids measured in ppm (parts per million) or yeast, filter aid and
mg/litre. bottle labels.
C.O.D. Chemical oxygen demand. The amount of Organic material like
‘work’ that the effluent plant has to do to spent grain, trub and
break the effluent down to a quality that can yeast.
be discharged into a local river.
B.O.D. Biological oxygen demand. Similar to C.O.D. Organic material like
spent grain, trub and
yeast.
pH A measure of the acidity/alkalinity of the Detergents and beer.
effluent. Water is neutral at 7.
Temperature. A measure of the heat in the effluent. Hot effluent from the
brewhouse,
boilerhouse or
pasteurisers.
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Reduction in Effluent loading.
Effective monitoring is necessary for the control of effluent. This is usually

done using flow meters, by sampling the effluent to measure its suspended
solids and COD and by sensing for pH and temperature. Swift detection of
problems, for example yeast being washed to drain can help manage the
costs of effluent.
Taking individual samples of effluent, of course will only provide information

on the state of the effluent at a particular point in time.
The ‘Pie Charts’ below illustrate how the various areas of a brewery influence
the effluent picture:
Brewery Effluent Volume
Filtration
Fermentation
Bottle washer
Brewhouse
Pasteuriser
Fillers
Brewery Effluent Solids
Trub
Lauter Tun
Pasteuriser
Filler
Fermentation
Bottle Washer
Filtration
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Brewery Effluent COD
Trub Lauter Tun
Pasteuriser
Filler
Bottle Washer
Filtration
Fermentation
Packaging effluent can be reduced by taking the following action:
Source of Effluent Control Methods
Bottle washing machines. • Run at the specified speed to limit

water ‘carry over’.
Please note that modern plant is designed • Maintain detergent strengths at the
to reduce effluent and that operating the specified levels to keep the system in
plant as recommended by the balance.
manufacturers is essential. • Collect dumped detergent in settling
tanks and dispose of by alternative
methods.
Keg washing machines. • Ensure that the cycle timers are
operating as specified.
Operating the plant as recommended by • Maintain detergent strengths at the
the manufacturers is essential. specified levels.
• Recycle washing water.
Filling machines. • Maintain to reduce bottle breakages.
• Maintain to control filling heights.
Please note that modern plant is designed • Make use of burst bottle detectors.
to reduce effluent and that operating the • Control over foaming.
plant as recommended by the
manufacturers is essential.
Tunnel pasteurisers. • Run at the specified speed to limit

water ‘carry over’.
• Maintain and check to control
temperature to specified levels.
Line stoppages. Ensure rinsing water and line lubrication
is automatically switched off.
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Effluent Costs
The authorities which operate the effluent plants often have particular
problems to resolve and their charging policies reflect these. The charge for
discharging effluent generally takes into account volume, suspended solids
and COD and these values are used in a formula eg Mogden to calculate the
cost per unit of effluent.
Individual authorities may adjust the formula itself to reflect their own
problems.
Notes:
Identify the charges for your own brewery and how they are calculated:
Statutory Controls
Water Authorities generally impose limits to the amount of and condition of
effluent being discharged from a brewery into their systems. They can levy
penalties and fines to companies who persistently exceed the limits.
A typical set of limits is detailed in the table below:
Parameter Limit
Maximum volume 100,000 litres per 24 hours
Maximum suspended solids 500 mg/litre
Maximum COD 10,000 kg per 24 hours
pH range 6 - 10
Maximum temperature 40o C
Notes:
Identify below the limits set for your brewery.

GCP Sect18 Water and Effluent

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1

Institute of Brewing and Distilling

Borehole Water: Surface Water:

Rain Bore hole

The Principal Characteristics and Requirements of a Brewery Water

Source Mineral Salt Microbiological Taints

Public Depends on Likely to be low Likely to be Very good

A Brewery Water Supply should have the following characteristics:

Water used in a Brewery can be identified as:

Methods for Pre-treatment of Water.

Some water sources require no treatment at all, so the selection of a ‘perfect’

Quality Standard Treatment

De-ionisation (removal of the salts) in Ion exchange columns is common in

In the plant illustrated below, Carbonates are removed in ion exchange

Acid regeneration tank

Alternative primary treatments are:

• Sand filtration for the removal of solids.

• Carbon filtration for the removal of flavour taints like chlorine.

• Ion exchange columns for de-mineralisation or de-alkalisation.

• Membrane filters or reverse osmosis. Reverse osmosis is a process where

• Removal of iron or manganese using a BIRM filter.

The plant illustrated has the following features:

Methods for Sterilising Water.

18.2. De-aerated, Process and Service Waters and Water

De-aerated water is that water used for:

• Additions make up.

Water Use Quality Requirements Treatment

Process water is that water used for:

• Cleaning brewery plant.

Water Use Problems Treatment

Cooling Tower Water:

General Cleaning Water:

Water usage Ratios, Conservation Methods and Costs.

Water is an expensive commodity, it is charged for by the Water Authority

18.3 Sources of Effluent and Measurement.

Effluent is the waste material discharged to the brewery drains. It is expensive

Sources in Brewing and Packaging operations

B re w h o u s e F e r m e n ta tio n F iltr a tio n

Value Explanation Source

Reduction in Effluent loading.

Effective monitoring is necessary for the control of effluent. This is usually

Taking individual samples of effluent, of course will only provide information

Brewery Effluent Volume

Brewery Effluent Solids

Brewery Effluent COD

Trub Lauter Tun

Packaging effluent can be reduced by taking the following action:

Source of Effluent Control Methods

Bottle washing machines. • Run at the specified speed to limit

Tunnel pasteurisers. • Run at the specified speed to limit

A typical set of limits is detailed in the table below:

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