The Diploma in Brewing Qualification (Dipl.

Brew)
Full Examination Syllabus
(Valid from June 2009)

© Institute of Brewing and Distilling 2013

 THE DIPLOMA IN BREWING QUALIFICATION
BACKGROUND

The Mission Statement of the Institute of Brewing & Distilling (IBD) is:

”To be recognized as the world’s leading members organization for the advancement of education and training
in the science and technology of brewing, distilling and related industries”.

The most senior examination is the Master Brewer (formerly DMB). This is a measure of the level of competence of the
candidates in the technical management of the beer process. Although it is a competence-based assessment, it is essential
that the candidates have a background, which includes a detailed knowledge of the theory that underpins the process. This
is why it is not permitted for candidates to sit this examination, without having previously reached the Diploma in Brewing
standard, either by examination or by exemption. The Institute awards successful candidates the use of the post-nominal,
“M.Brew”.

The Master Brewer Examination is the top professional qualification. Typical candidates are team leaders or
operational/technical managers in breweries. Successful candidates are considered to be sufficiently technically competent
to take up senior production management positions in the industry.

The next level is the Diploma in Brewing (formerly AME). The Diploma in Brewing is a measure of the candidates’
theoretical knowledge of brewing science and technology. Although there is a certain amount of practical knowledge
required, there is not any measure of competence, which is best described as a combination of knowledge and experience;
it requires the ability to learn from what has happened in the past, together with interpretative skills.

Typical Diploma in Brewing candidates are team leaders, operational managers and technicians. They take the Diploma in
Brewing either as a stepping stone to the Master Brewer Examination or as an end in itself. It provides them with the
theoretical knowledge that enables them to do their jobs better by improving the basis on which decisions are taken. The
Institute will award successful candidates the use of the post nominal “Dipl. Brew”.

The third level is the General Certificate in Brewing or General Certificate in Packaging (GCB or GCP). These are a measure
of the basic knowledge (theoretical and practical) underpinning brewing, packaging and associated operations. They are
aimed at team members, team leaders and technicians, who may lack formal educational qualifications and are thus not
able to have the basic scientific knowledge to sit the Diploma in Brewing. They are also suitable for other brewery
personnel (e.g. in HR, accounts, logistics, and engineering) who will benefit from a basic understanding of brewing and
packaging operations. The GCB and GCP can be an end in themselves, equipping successful candidates to carry out their
tasks more professionally. They can also be the start of professional development, leading to the Diploma in Brewing and
potentially, the Master Brewer Examination.

THE DIPLOMA IN BREWING

The objective of the Diploma in Brewing is to give international recognition of comprehensive knowledge and
understanding of the principles of Brewing Science and Technology. It is a measure of the candidates’ theoretical
knowledge of brewing science and technology. It is an important qualification in its own right, as well as representing the
necessary thorough grounding for the application of those principles for the Master Brewer Examination.

The examinations are arranged in 3 Modules, covering respectively the Science of Materials and Wort; the Science of Yeast
and Beer; Packaging and Process Technology. There is some overlap when both science and technology are applied to the
same topic.

Modularisation of the syllabus and examinations is designed to allow for a wide range of candidates' scientific backgrounds.
Whereas those with appropriate science degrees might choose to take all three examinations within a year of commencing
study, the syllabus is equally applicable to those with appropriate work experience offsetting less advanced academic
qualifications. Hence, the opportunity to tackle the required reading matter piecemeal over a period of time is likely to be
welcomed by many.

Whilst there is neither educational qualification nor work experience specified for sitting the examinations, potential
candidates must satisfy themselves that they have sufficient scientific knowledge to understand the subject matter.
Guidance is offered in the next section.

2 IBD Diploma in Brewing

ADVICE TO CANDIDATES

The syllabus of each Module is divided into units, which cover a topic area e.g. “Unit 1.8 Mashing and Wort Separation”.
Each unit is then sub-divided into elements and in the example above, there are 4 elements covering the science and
technology associated with this unit. Each element then has text associated with it to describe the level of detail required.
Thus the syllabus is presented in considerable detail and candidates are advised to use it as a revision tool and to tick off
each element as part of their examination preparation.

Unless otherwise stated, candidates are expected to achieve a detailed understanding of a topic; consistent with the
objectives of the examination. The adjectives “basic” and “outline” are used when a lesser depth of knowledge is required.

“The basic concept of …” means the ability to explain all the major principles, functions or purpose relevant to the topic,
without the need to describe its intricacies.

“An outline of …” means a summary description of the scientific principles, plant or process concerned.

Where there are references in the syllabus to chemical compounds, candidates are expected to know the scientific
principles and significance of their role in the process. Knowledge of complex formulae and advanced chemistry is not
required.

Where there are references in the syllabus to mathematical equations & simple calculations, candidates are expected to
use straightforward mathematics in the specified applications relevant to brewery operations. Commitment to memory of
complex equations and formulae is not required. However, candidates are expected to know the basic formulae, which
govern key scientific principles.

Candidates are strongly advised to acquire an experienced Mentor for their period of study, capable of providing the
initial advice on minimum scientific comprehension (as indicated in the above definitions), followed by general direction,
support and assessment of progress through a Module.

EXAMINATION DETAILS

Qualification to sit the Diploma in Brewing is Membership of the Institute of Brewing & Distilling.

The three Modules may be sat in any order, and there are no time limits for sitting one or all of the Modular Examinations.

REGISTRATION FOR EXAMINATION

The Diploma in Brewing takes place in June of each year.

Candidates must register with the Institute by 1st November of the previous year. Registration fees and any special
conditions are published regularly in the Institute's publications.

ISSUE OF CERTIFICATED QUALIFICATIONS

The Institute of Brewing & Distilling will separately certificate each Module, with success in all three Module Examinations
qualifying for the use of post nominals, “Dipl.Brew”. Successful candidates will receive a Diploma in Brewing certificate.

EXAMINATION ENQUIRIES

Please address all enquiries and correspondence to:

The Examinations Department

The Institute of Brewing & Distilling
33 Clarges Street
London
W1J 7EE

Tel: +44 (0) 20 7499 8144 E-mail: exams@ibd.org.uk

Fax: +44 (0) 20 7499 1156 Web: www.ibd.org.uk

Syllabus 2013 3
 DIPLOMA IN BREWING - SYLLABUS INDEX

MODULE 1 – MATERIALS & WORT PRODUCTION (Page 5 – 12)

MODULE 2 – BEER AND YEAST (Page 13 –20)

MODULE 3 – PACKAGING TECHNOLOGY AND PROCESS TECHNOLOGY (Page 21 – 34)

MODULE 1 MATERIALS AND WORT Page

1.1 Barley 5
1.2 The Malting Process 5
1.3 Malt Quality and Brewhouse Performance 6
1.4 Adjuncts and Speciality Malts 6
1.5 Water 7
1.6 Hops and Hop Products 8
1.7 Malt Processing in the Brewery 8
1.8 Mashing and Wort Separation 9
1.9 Wort Boiling and Cooling 10
1.10 Effluent 10
1.11 Quality 11

MODULE 2 YEAST AND BEER

2.1 Yeast Fundamentals 13
2.2 Basic Yeast Metabolism 13
2.3 Fermentation 14
2.4 Yeast in Brewing 14
2.5 Maturation and Cold Storage 15
2.6 Beer Clarification 16
2.7 The Properties of Beer 17
2.8 Beer Flavour 18
2.9 Beer Spoilage Organisms 19
2.10 Quality 20

MODULE 3 PACKAGING TECHNOLOGY AND PROCESS TECHNOLOGY

3A - PACKAGING TECHNOLOGY
3.1 Packaging Materials 21
3.2 Unit Packaging Operations 21
3.3 Sterile Filtration and Pasteurisation 22
3.4 Packaging Line Design and Performance 23
3.5 Quality 23

3A and 3B – PACKAGING AND PROCESS TECHNOLOGY

3.6 Process Gases 25

3B - PROCESS TECHNOLOGY
3.7 Fluid Flow 26
3.8 Principles of Heat Transfer 27
3.9 Steam 29
3.10 Refrigeration 29
3.11 Materials of Construction 31
3.12 Process Control and Instrumentation 32
3.0 SI Units (information only, not examinable) 34

This document is Copyright of the Institute of Brewing & Distilling © 2013

4 IBD Diploma in Brewing

MODULE 1 - MATERIALS AND WORT

UNIT 1.1 BARLEY

1.1.1 The structure and morphology of barley grains and plants

Structure of the grain:
- endosperm
- aleurone layer
- embryo
- husk, pericarp and testa
Relevant differences between 2-row and 6-row barleys

1.1.2 The physiological and biochemical changes occurring during barley germination
Mechanisms of water uptake
Dormancy
Water sensitivity
Activity in the embryo and aleurone
The role of gibberellins
Endosperm modification:
- cell wall breakdown
- starch breakdown
- protein degradation

1.1.3 Evaluation of barley for malting

Desirable characteristics of barley for malting:
- the effect of nitrogen content
- the effect of endosperm structure
- the effect of cell wall composition
- dormancy limits
- the effect of pre-germination
- the effect of husk content
- the effect of size distribution
Methods of assessing suitability for malting:
- micromalting techniques
- germinative capacity and energy tests
- water sensitivity tests
- extract recovery tests

1.1.4 Principles of barley breeding and selection for malting

Principles of genetic enhancement of barley
- Commercial breeding methods
The importance of:
- disease resistance
- yield
- stability
Methods used in barley identification:
- morphological
- gel electrophoresis

UNIT 1.2 THE MALTING PROCESS

1.2.1 Barley intake and storage

The need for testing at intake
- the principal tests
Principles of barley screening
The need for barley drying
- principles of drying barley
- control and monitoring of moisture content
- consequences of poor storage and moisture control
Control of pests and diseases

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 1.2.2 Steeping
The basic principles of design and operation of modern steeping vessels -
The physical and biochemical changes required to take place during steeping
The range of operating controls available to the process
- their effects on the grain and ultimate malt quality
Principles of barley abrasion
- the effect on malting performance

1.2.3 Germination
The basic principles of design and operation of modern germination systems
The physical and biochemical changes required to take place during germination
The range of operating controls available to the process:
- their effects on the grain and ultimate malt quality
- the control of malting loss
The use of gibberellic acid and bromate
- methods of application
- advantages and disadvantages

1.2.4 Kilning
The basic principles of design and operation of a malt kiln
- the respective merits of direct and indirect heating
The physical and biochemical changes required to take place during kilning
The range of operating controls available to the process
- their effects on the malt and its quality
Calculation of malt yield
- a typical acceptable range of values

UNIT 1.3 MALT QUALITY AND BREWHOUSE PERFORMANCE

1.3.1 The requirements of a malt of good quality

High extract recovery
Ease of milling
Ease of extract recovery
Low viscosity wort
The required balance of nitrogenous compounds
Wort clarity
Wort of the desired colour

1.3.2 Typical specification ranges for ale and lager malts

Hot water extract Moisture
Cold water extract Diastatic power
Fine / coarse difference Dextrinising units
Total nitrogen Colour
Total (or partial) soluble nitrogen Friability
Soluble nitrogen ratio Homogeneity
Free amino nitrogen Dimethyl sulphide
S-methylmethionine
The reasons for any differences

UNIT 1.4 ADJUNCTS AND SPECIALITY MALTS

1.4.1 The range of adjuncts available and their typical composition

Syrups from hydrolysed starch
- typical carbohydrate spectra
Sucrose based products
Processed solid adjuncts
Unprocessed solid adjuncts
An outline understanding of the principles of manufacture

1.4.2 The applications of adjuncts in the brewery

Control of wort fermentability

6 IBD Diploma in Brewing

 The effects on beer stability
Contributions to beer flavour
The effect on brewhouse capacity
Priming of beers
Examples of the use of extraneous enzyme additions (see also 1.8.1)

1.4.3 Speciality malts

The basic principles of manufacture, application and typical specification ranges for:
- chocolate, roast malts
- crystal, carapils malts
- high diastatic power enzymic malt
- high beta-glucanase enzymic malt
- roasted barley

UNIT 1.5 WATER

1.5.1 Characteristics
The characteristics of potable water and the reasons for having limits acceptable for brewing:
- microbiological contamination
- commonly found organic compounds
- commonly found anions
- commonly found cations

1.5.2 Composition
The meaning of:
- temporary hardness
- permanent hardness
- total hardness
- calcium hardness
- magnesium hardness
- total alkalinity
The relevance to brewing of the following components of brewing liquor:
- calcium - ammonium
- magnesium - carbonate
- sodium - bicarbonate
- potassium - sulphate
- iron - chloride
- copper - nitrate
- manganese - free chlorine
- zinc - free CO2

1.5.3 Treatment
The principles, functions and respective merits of methods for treating brewing liquor:
- lime treatment
- acid addition
- salt addition to the liquor
- salt addition to the mash
- demineralisation
- selective ion removal
- activated carbon
- reverse osmosis
- ultrafiltration
- sterilisation techniques
The basic principles of design and operation of water treatment plants
Methods of preparation of deaerated water:
- typical plant used
- the gas laws applicable to oxygen removal
- sterilisation of de-aerated water

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 UNIT 1.6 HOPS AND HOP PRODUCTS

1.6.1 Selection of hops

Criteria for selecting hops
Effects of pests and diseases
Effects of harvest conditions

1.6.2 Hop constituents relevant to brewing

Principal hop resins:
- alpha-acids and their relevance to brewing
- beta-acids and their relevance to brewing
- the principles of isomerisation
Essential oils:
- the hydrocarbons
- the oxygenated compounds
- the sulphur compounds
Tannins:
- their role in trub formation
The changes that occur during storage of hops and hop products

1.6.3 Processed hop products

The principles of manufacture, the active ingredients and typical uses in brewing of:
- unisomerised extracts
- isomerised extracts
- aroma extracts (including hop oils)
- standard hop pellets
- concentrated hop pellets (e.g., Type 45 & Pre-isomerised)
- speciality hop products

1.6.4 The use of hops in brewing

The principles of hop grist preparation
- calculation of hopping rate
- factors influencing choice of hop product
Measurement of hop utilisation
The importance of good hop storage
Dry hopping

UNIT 1.7 MALT PROCESSING IN THE BREWERY

1.7.1 Malt handling

The need for inspection tests at intake
The purpose of screening malt
The need for controlling dust
- a typical method of control
The relevance of consistency of corn size
Handling of speciality malts

1.7.2 Milling
The basic principles of the process from malt storage to grist ready for mashing
- the function of each item of equipment
The basic principles of design and operation of:
- four-roller dry mills
- six-roller dry mills
- hammer mills
- wet mills
- their respective merits
The relevance of particle size control in milling:
- the effect on subsequent extraction of malt components
- the effect on subsequent wort run-off
- the use of steam conditioning (or equivalent techniques) during milling
- typical ranges for husk : coarse grits : fine grits : flour ratios

8 IBD Diploma in Brewing

UNIT 1.8 MASHING AND WORT SEPARATION

1.8.1 The enzymic processes

The key processes underlying the conversion of malt and adjuncts to fermentable wort:
- the role of alpha-amylase
- the role of beta-amylase
- the role of limit dextrinase
- the role of proteases
- the role of beta-glucanase
- the role of extraneous enzyme additions
The influence of the following mashing conditions on the key enzymic activity:
- ionic composition
- pH, including the role of acidification methods
- time
- temperature
- grist : liquor ratio

1.8.2 Wort composition

The relevance of the following malt analyses for predicting wort composition and extraction efficiency:
- moisture content - fine / coarse difference
- hot water extract - soluble nitrogen ratio
- cold water extract - free amino nitrogen
- colour - beta-glucanase
- diastatic power - wort fermentability
- total nitrogen - wort viscosity
- soluble nitrogen - S-methylmethionine
- friability - homogeneity
Typical ranges in sweet wort, and the role of adjuncts in controlling the following:
- fermentable : total carbohydrate ratio
- the spectrum of fermentable carbohydrates
- amino nitrogen concentration
- spectrum of nitrogen compounds & their concentration

1.8.3 Mashing techniques

The basic principles of common mashing regimes:
- single temperature infusion mashing
- temperature-programmed mashing
- decoction mashing
- their respective merits in relation to:
- control of wort carbohydrate spectrum
- control of wort nitrogen spectrum
- extraction efficiency
- usable range of malt modification
- usable range of malt total nitrogen
- grist : liquor ratio
- selection of solid adjuncts
- selection of liquid adjuncts
- overall wort quality

1.8.4 Wort separation techniques

The theory of filtration applied to wort separation
The basic principles of design and operation of:
- a mash tun
- a lauter tun
- a mash filter
- their respective merits in relation to:
- run-off rates
- extract recovery
- general wort quality
Calculation of % extract recovery from raw materials

Syllabus 2013 9
 UNIT 1.9 WORT BOILING AND COOLING

1.9.1 Wort boiling

The chemical changes that take place during wort boiling:
- the formation and solubilisation of hop flavour components
- the fate and control of volatile flavour components
- the use of late hopping
- the relevance of enzyme inactivation
- the nature and significance of protein coagulation & trub formation
- the formation of colour
- the nature and relevance of pH changes
The basic principles of design and operation of wort kettles:
- with internal heating arrangements
- with external heating arrangements
- under pressure
- their respective merits in relation to:
- evaporation rates
- time of boil
- vigour of boil
- general wort quality

1.9.2 Wort clarification

The need for clarifying hot wort prior to cooling
Common hot wort clarification methods:
- hop back
- hop separator
- whirlpool
- centrifuge
- their respective merits in relation to:
- choice of hop products in the kettle
- effectiveness of trub removal
- use of trub precipitation aids

1.9.3 Wort cooling

The basic principles of design and operation of a plate heat exchanger for cooling wort
The relevance of controlling cold break formation
The initial oxygen requirements in wort for a typical pitching yeast
The respective merits of providing oxygen by:
- injecting oxygen vs. air into the wort
- injecting into hot vs. cold wort
- other techniques
Typical ranges for ales and lagers:
- wort temperatures at yeast pitching
- dissolved oxygen at yeast pitching

UNIT 1.10 EFFLUENT

1.10.1 Composition
The meaning and relevance to brewery effluent of:
- biological oxygen demand (BOD)
- chemical oxygen demand (COD)
- total suspended solids (TSS)
- total solids (TS)
- pH
- temperature
- water consumption (Volume)
The relative contributions of departments to the components of brewery effluent:
- the brewhouse
- fermentation & yeast handling
- maturation, conditioning & filtration
- packaging

10 IBD Diploma in Brewing

 Typical values for a brewery:
- water usage : beer production ratio
- effluent volume : beer production ratio
- BOD/COD levels
- TSS/TS levels
- pH range
A local method of calculating effluent costs
- typical limits of acceptability

UNIT 1.11 QUALITY

1.11.1 Quality Management

The difference between Quality Control and Quality Assurance
The basic principles of Quality Assurance concepts, including:
- international standards, e.g. ISO 9000 series
- HACCP
- right first time
- total quality management
The basic principles and purpose of standards for laboratory practice, e.g. NAMAS

1.11.2 Hygiene
The relevance of the nature of process plant internal surfaces
The relevance of pipework and fittings design
The principles of in-place cleaning (CIP)
The basic principles of design and operation of CIP systems for brewhouse plant
The range and main constituents of commercially available cleansing agents:
- detergents
- sterilising agents
- typical usages on stainless steel
- hot
- cold
- typical usages on other plant materials
Detection and quantification of residual surface contamination:
- visual inspection
- rinse sampling
- swab sampling
- media plating applications
- forcing tests
- bioluminescence testing

1.11.3 Laboratory Analysis

The basic concepts applied to interpretation of analytical data:
- sampling error
- accuracy & precision
- repeatability (r)
- reproducibility (R)
- specification ranges (tolerances)
- simple probability calculations:
- normal distributions
- standard deviation
- variance
The relevance of inter-laboratory collaborative checks
The basic principles of analytical techniques for:
- malt, adjuncts, wort (where relevant):
- hot water extract - dimethyl sulphide (free and total)
- total nitrogen - friability
- total soluble nitrogen - diastatic power
- moisture - wort viscosity
- colour - spent grains
- free amino nitrogen
- S-methylmethionine

Syllabus 2013 11
 - hop resins by:
- lead conductance value
- spectrophotometry
- ion exchange chromatography
- HPLC
- hop essential oils by:
- steam distillation
- GLC
- effluent:
- BOD
- COD
- Total suspended solids
- water:
- pH
- anions
- cations
- hardness
- taste
- potential contaminants (outline principles only)

12 IBD Diploma in Brewing

MODULE 2 - YEAST AND BEER

UNIT 2.1 YEAST FUNDAMENTALS

2.1.1 Yeast Morphology

Key features and functions of a yeast cell:

- the cell wall
- the plasma membrane
- the nucleus
- the cytoplasm
- the mitochondria
Mechanism of growth and cell division (budding)

2.1.2 Genetic characteristics of yeast

The outline of genetic tests for typing yeasts (e.g., DNA fingerprinting)
The principles of modifying the genetic composition of yeast
- potentially useful applications in brewing

2.1.3 Characteristics of brewing yeasts

The principles of distinguishing ale from lager yeasts:
- selective media
- incubation technique
- colony morphology
The use of small-scale fermenters for evaluating yeasts (e.g., tall tube)
The evaluation of flocculation characteristics
The outline of biochemical tests for characterising yeasts:
- sugar metabolism
- resistance to inhibitors
- immunological reactions

UNIT 2.2 BASIC YEAST METABOLISM

2.2.1 Carbohydrate metabolism

The selective mechanisms for:
- transferring carbohydrate through the cell wall
- conversion to fermentable sugars
The carbohydrates not utilisable by normal brewing yeasts
The basic differences between aerobic and anaerobic carbohydrate metabolism
The main purpose and effects of the Embden-Meyerhof-Parnas pathway
- the equation for converting glucose to ethanol and CO2
- the quantity of energy thus generated
- the capture of energy through NAD and ATP
The significance of pyruvate in the metabolic chain:
- its function as a source of ethanol
- its function as a precursor of other key molecules
The importance of glycerol production in NAD/NADH balance
The importance of the pentose-phosphate pathway in:
- biosynthesis
- NADPH production

2.2.2 Production of flavour compounds

The basic principles of the main production biochemical mechanisms, flavour descriptors and thresholds for:
- acetaldehyde - vicinal diketones
- fatty acids - dimethyl sulphide
- the main higher alcohols - hydrogen sulphide
- the main esters - other sulphur volatiles
- the main organic acids
See 2.8.2 for other flavour components of beer

Syllabus 2013 13
 2.2.3 Basic nutritional requirements of yeast
The sources of the carbon, hydrogen, nitrogen, oxygen, salts and growth factors necessary to promote
healthy yeast growth and fermentation
- The components of brewers' wort that are not utilised by yeast
- The role of molecular oxygen

UNIT 2.3 FERMENTATION

2.3.1 Principal Fermentation Variables

Typical ranges, for ales and lagers, of:
- wort strength
- yeast pitching rate
- pitching temperature
- max. fermentation temperature
- wort dissolved oxygen
- wort total nitrogen
- wort alpha-amino nitrogen
- wort fermentable carbohydrate (% of total)
- alcohol strength
- fermentation pressure
- pH

2.3.2 The effect of fermentation variables

The effect of the above variables on rate of fermentation and formation of beer flavour components, and the
main reasons for such effects:
- acetaldehyde - vicinal diketones
- fatty acids - dimethyl sulphide
- higher alcohols - hydrogen sulphide
- esters - other sulphur volatiles
The basis of alcohol sensitivity/tolerance in yeast

2.3.3 Principles of operational techniques

The basic principles of design and operation of:
- a modern fermenting vessel
- a modern dual purpose fermenting/maturation/conditioning vessel
- the relative merits of separate vs. dual purpose vessels
- basic design differences between ale and lager vessels
The basic principles of fermentation control
The basic principles of continuous fermentation
- advantages and disadvantages vs. batch
The basic principles of yeast immobilisation
- potential applications in brewing
The basic principles of high gravity brewing
- factors that limit wort strength
- the impact of high gravity brewing on:
- beer flavour
- fermentation and maturation processing
- quality requirements for dilution water

UNIT 2.4 YEAST IN BREWING

2.4.1 Yeast cultures

The principles of isolating pure cultures:
- from a single cell source
- from a mixture of single cell isolates
- from a plate colony
- their respective merits
The principles of preserving pure cultures in the laboratory:
- liquid media techniques
- freeze drying
- deep freezing
- solid media techniques

14 IBD Diploma in Brewing

 - their respective merits
- techniques for minimising contamination
- techniques for minimising changes in brewing characteristics
The principles of yeast propagation:
- laboratory techniques for growing cultures for commercial propagation
- the means of ensuring viability and sterility
- the basic principles of design and operation of yeast propagators

2.4.2 Measurement of quantity and quality

Methods for measuring yeast concentration:
- plate count
- haemocytometer
- turbidity
- biomass probe
- their relative merits in practice
Methods for assessing yeast viability and vitality, including:
- methylene blue
- CO2 evolution
- acidification power
- sterol content
- oxygen uptake rate
- their relative merits in practice
Measurement and calculation of yeast growth in a brewery fermentation:
- rate of growth
- total quantity produced
- typical ranges of yeast multiplication during fermentation:
- ales
- lagers
- the effect of pitching rate

2.4.3 Yeast handling and management

The basic principles and reasons for storing yeast for repitching:
- as pressed yeast
- in liquid suspension
- the use of acid washing
The use of yeast for repitching:
- selection criteria
- typical yeast concentrations required in worts at pitching
- techniques for physical preparation of yeast for pitching
- methods of measurement
The role of and methods for reculturing pitching yeast
- typical programmes
- typical scale-up regimes

2.4.4 Physical behaviour of yeast

The basic principles of yeast - yeast and yeast - non-yeast interactions:
- flocculation
- sedimentation
- adhesion

UNIT 2.5 MATURATION AND COLD STORAGE

2.5.1 General principles

The basic principles of design and operation of modern conditioning tanks designed for beer processing
above and below 0°C
- processing above 0°C:
- techniques for developing desired flavours
- techniques for control of undesired flavours
- control of vicinal diketones
- control of CO2 content to desired values

Syllabus 2013 15
 - modern methods of flavour conditioning:
- use of acetolactate decarboxylase
- use of flavour ingredients
- basic principles of continuous maturation
- advantages and disadvantages vs batch
- processing below 0°C:
- the purpose of chilling below 0°C
- the mechanism of precipitating from solution
- the mechanism of settlement of solids
- the relevance of time held below 0°C

2.5.2 Processing aids

The nature, purpose and function of typical processing aids:
- finings
- silica gels
- PVPP
- proteolytic enzymes
- alginates

2.5.3 Additions to beer

The nature, purpose and function of typical additions to beer:
- hop products
- sugars and syrups
- caramels
- enzymes

UNIT 2.6 BEER CLARIFICATION

2.6.1 Sedimentation and centrifugal sedimentation (centrifugation)

The theory of sedimentation and centrifugal sedimentation
- simple sedimentation and centrifugation calculations
The basic principles of design and operation, the respective merits and typical brewery applications of:
- an opening bowl centrifuge
- a decanter centrifuge
The factors affecting the machine’s capacity to clarify to a desired solids concentration:
- typical solids concentrations in and out, the reasons for tight controls of solids levels ex centrifuge
and the principal threats to beer quality when
- processing beer ex fermenter
- processing beer prior to filtration

2.6.2 Filtration
The theory of filtration
- simple calculations on filtration
The principles of beer filtration:
- using filter powders
- using sheet filtration
- using cross-flow techniques
- using depth filtration
The relevance of temperature control during filtration
The relevance of micro-organism concentrations:
- in the beer presented to the filter
- in the filtered beer
The nature, function and available materials for the following:
- using filter aid:
- the support for the medium
- pre-coat filter aid
- main filter medium
- using other processes:
- for polishing
- for sterilisation
- for beer recovery

16 IBD Diploma in Brewing

 The basic principles of design and operation and the respective merits of:
- a plate and frame filter
- a leaf filter
- a candle filter
- a cross flow filter
- a sterilising filter
The principles of filter performance as a function of:
- time
- pressure
- filter medium dosing
- beer solids concentration

UNIT 2.7 THE PROPERTIES OF BEER

2.7.1 Beer Hazes

The nature and typical composition of:
- biological hazes
- chill hazes
- permanent hazes
The scientific principles behind, and relevance of process factors in non-biological haze formation:
- malt as a source of proteins, polyphenols and glucans
- mashing temperatures and pH
- hops as a source of polyphenols
- wort boiling conditions
- the relative merits of process aids in conditioning:
- adsorbents
- enzymes
- oxygen availability throughout the process
- beer process temperatures
The measurement of non-biological haze by turbidity meter
- the effect of angle of scatter
- "invisible" haze
- the effect of beer colour
The prediction of shelf-life in packaging using accelerated haze formation techniques

2.7.2 Beer Foam

The physical principles of:
- foam formation
- foam collapse
- lacing (foam adhesion)
The role of surface activity in foam behaviour
Common methods for measuring foam quality
The role of the following, and their effect on foam behaviour:
- polypeptides
- bitter substances including reduced hop products
- lipids
- CO2
- N2
- metal ions
- polysaccharides
- temperature
- ethanol
The scientific principles of the use of foam stabilisers:
- alginates
The way in which process factors can affect beer foam stability:
- grist materials
- mashing techniques
- wort boiling regimes
- beer transfer techniques
- gas injection

Syllabus 2013 17
 - container filling procedures
- colloidal stabilisation treatments
The way in which conditions in a retail outlet can affect foam and foam stability in dispensed beer:
- gas (CO2, N2) levels in the beer
- flow characteristics through the beer pipe
- design of dispense tap
- glass washing techniques

2.7.3 Colour in Beer

The basic constituents of melanoidins in beer
- their origins in malting and brewing
- the conditions for melanoidin formation
- their main flavour effects
The contribution of polyphenol oxidation to beer colour
The use of caramel and other materials for colour addition:
- in wort and beer
- the method of calculating additions
The basic constituents of colouring preparations suitable for brewery use
The process factors that can affect and control colour formation and flavour:
- malt specifications
- temperatures
- heating times and conditions
The principles of measuring colour in wort and beer
- methods based on colour comparison
- photometric methods
- tristimulus and chromaticity

2.7.4 Gushing in Beer

The essential scientific basis of gushing
The relevance to gushing of:
- grain infection
- beer particulates
- oxidised hop compounds
The basic principles of techniques for predicting gushing potential in raw materials

UNIT: 2.8 BEER FLAVOUR

2.8.1 Assessment techniques

The basic facilities and disciplines necessary to conduct taste testing
The method, typical applications and ways of reporting, for the following procedures:
- Difference tests:
- triangle taste test - A or not-A test
- paired comparisons - Two out of 5 test
- duo-trio test
- Descriptive tests:
- flavour profile - drinkability
- ranking tests - threshold tests
- trueness-to-type
The interpretation of "statistical significance" results
The role of flavour standards and training

2.8.2 Beer flavour components

The nature and contribution to beer flavour of:
- iso-alpha-acids - hop oils
- residual sugars, dextrins - ethanol
- inorganic ions - CO2
- non-volatile malt components
See 2.2.2 for volatile flavour components produced by fermentation

18 IBD Diploma in Brewing

 The nature and origin of common flavour taints, including:
- phenolic
- musty
- plastic
- metallic

2.8.3 Flavour stability

The nature of flavour changes which occur during beer storage
The importance of oxygen and oxidation in causing flavour instability
The broad mechanisms by which cardboard flavours are understood to develop:
- enzymic
- non-enzymic
The use of antioxidants to control flavour deterioration
The influence which separate process stages can have in determining flavour stability

UNIT 2.9 BEER SPOILAGE ORGANISMS

2.9.1 Types of organisms

The organisms which can spoil worts and beers, their typical growth conditions and the effects that they
have:
- Acetobacter - O. Proteus
- Gluconobacter (Acetomonas) - Pectinatus
- Lactobacillus - Enterobacter agglomerans
- Pediococcus - Bacillus
- Zymomonas - wild yeasts
- Megasphaera

2.9.2 Detection methods

The principles of detection and quantification of organisms, and their specific applications to the above beer
spoilage organisms:
- microscopic examination
- selective media aerobic
- anaerobic
- membrane filtration
- plate tests
- forcing tests
- bioluminescence
- other rapid methods

2.9.3 Control factors

The factors in brewing practice that affect susceptibility/tolerance of the above beer spoilage organisms to
grow in wort or beer:
- source of carbon
- source of nitrogen
- molecular oxygen
- hop substances
- temperature
- pH
- alcohol

Syllabus 2013 19
 UNIT 2.10 QUALITY
2.10.1 Quality Management
The difference between Quality Control and Quality Assurance
The basic principles of Quality Assurance concepts, including:
- international standards, e.g. ISO 9000 series
- HACCP
- right first time
- total quality management
The basic principles and purpose of standards for laboratory practice, e.g. NAMAS

2.10.2 Hygiene
The relevance of the nature of process plant internal surfaces
The relevance of pipework and fittings design
The principles of in-place cleaning (CIP)
The basic principles of design and operation of CIP systems for fermentation, yeast handling, maturation,
cold storage and filtration plant
The range and main constituents of commercially available cleansing agents:
- detergents
- sterilising agents
- typical usages on stainless steel
- hot
- cold
- typical usages on other plant materials
Detection and quantification of residual surface contamination:
- visual inspection
- rinse sampling
- swab sampling
- media plating applications
- forcing tests
- bioluminescence testing

2.10.3 Laboratory Analysis

The basic concepts applied to interpretation of analytical data:
- sampling error
- accuracy & precision
- repeatability (r)
- reproducibility (R)
- specification ranges (tolerances)
- simple probability calculations:
- normal distributions
- standard deviation
- variance
- The relevance of inter-laboratory collaborative checks
The basic principles of analytical and on-line measurement techniques for:
- original gravity - vicinal diketones
- alcohol content - metals
- dissolved carbon dioxide - other inorganic cations relevant to beer quality
- dissolved oxygen - inorganic anions relevant to beer quality
- dissolved nitrogen - dimethyl sulphide
- bitterness - other flavour components relevant to beer quality
- specific gravity - carbohydrates
- pH - nitrogenous constituents
- SO2

20 IBD Diploma in Brewing

MODULE 3 PACKAGING TECHNOLOGY AND PROCESS TECHNOLOGY

SECTION 3A PACKAGING TECHNOLOGY

UNIT 3.1 PACKAGING MATERIALS

3.1.1 Packaging Materials for Small Pack

Understanding of Primary, Secondary and Tertiary Packaging
- Primary Packaging Materials
- A basic understanding of the importance of
- basic properties
- marketing impact
- legal impact
- environmental effects
- The basic principles of manufacture of bottles, cans, crowns and ends
- method of manufacture
- choice of materials
- choice of linings
- typical faults
- Secondary Packaging Materials
- A basic understanding of the importance of
- function
- basic properties
- marketing impact
- legal impact
- environmental effects
- A basic understanding of the impact of secondary packaging on the operation of the
ackaging line and on the appearance of the package

3.1.2 Packaging Materials for Large Pack

The basic principles of manufacture of kegs, spears and casks
- method of manufacture
- choice of materials
- choice of linings
- typical faults
- the impact of the materials and linings on the properties of beer
- the use of transponders for container tracking.

UNIT 3.2 UNIT PACKAGING OPERATIONS

3.2.1 Bottling and Canning - Basic Principles

Introduction to packaging line components
The basic principles of design and operation of a modern bottle washer
- selection of washing conditions dependent on:
- the variety of commercially available labels and foils
- the variety of commercially available adhesives
The basic principles of design and operation of a modern bottle and can rinser
The basic principles of design, operation and control of bottle fillers/ crowners (nonsterile) and can fillers/
seamers (non-sterile) for carbonated beverages
- typical methods of controlling dissolved oxygen levels
- typical methods of controlling bottle fill levels
The basic principles of design and operation of a bottle labeller

Syllabus 2013 21
 3.2.2 Bottling and Canning - Plant Features
The basic plant features and control procedures, from filtration through to filled containers, which minimise:
- beer dilution
- variations in beer CO2 levels
- O2 pick-up
- loss of foam potential
- particulate matter in the beer
- microbiological contamination

3.2.3 Sterile Filling of Bottles and Cans

The basic principles a sterile filling operation, from sterile filtration or flash pasteurisation to bottle or can
- filler installation and layout
- filler environment
- methods of ensuring a sterile filling operation
- methods of closure cleaning
- plant cleaning and CIP
- training of personnel
- microbiological backup

3.2.4 Keg Racking

The basic principles of design, operation and control of modern combined keg cleaning/filling machines
- the choice of detergent, concentration and temperature
- typical regimes during the cleaning, sterilising and filling cycles
- the relative merits of inverted versus upright filling
- methods of controlling keg fill levels
- the merits of using gases other than CO2 , as the top pressure gas in kegging operations

3.2.5 Basic Principles of Beer Preparation, and Design, Operation and Control of Cask Cleaning / Filling Plant
Cask process and beer condition
Beer finings – procedures and materials
Hop product addition
Choice of detergent, concentration and temperature
Typical regimes for cleaning, sterilising and filling casks
Shive / keystone removal and insertion

3.2.6 The Basic Plant Features and Control Procedures from Filtration through to Filled Containers
Plant features and procedures designed for:
- minimising beer dilution
- control of CO2 (and N2) levels
- control of O2 pick-up
- control of beer foam
- particulate matter in the beer – generation and control
- control of microbiological contamination
- washing and filling monitoring
- use of steam

UNIT 3.3 STERILE FILTRATION AND PASTEURISATION

3.3.1 Sterile Filtration

Process specification
Filtration mechanisms
Filter types (including cross-flow filtration)
Removal ratings
Filter flow characteristics

22 IBD Diploma in Brewing

 Integrity testing
Filter cleaning (CIP)

3.3.2 Principles of pasteurisation

The definition and aims of pasteurisation
The relationship between time and temperature on lethal rate
The effect of pasteurisation on different organisms
The definition of pasteurisation unit (PU)
Simple calculations on the relationship between pressure, temperature and CO2 content

3.3.3 Plate (Flash) Pasteurisation

The basic principles of design, operation and control of a flash pasteuriser
Heat regeneration level
Typical operating parameters
Principal effects on beer quality during pasteurisation
Pasteuriser system design and control

3.3.4 In-package or Tunnel Pasteurisation for Small Pack

Basic principles of design
Beer flavour damage
Measurement of PUs
Chemical treatment of pasteuriser water

UNIT 3.4 PACKAGING LINE DESIGN AND PERFORMANCE

3.4.1 Packaging Line Design Theory

A basic understanding of packaging line design theory
“V” graph
Line availability
Accumulation
Use of variable speed equipment
Handling materials
Handling rejects and waste

3.4.2 Packaging Line Performance

The principles of packaging line performance assessment
Yield
Operating efficiency
Utilisation
A basic understanding of systems to measure performance

UNIT 3.5 QUALITY

3.5.1 Quality Management

The difference between Quality Control and Quality Assurance
The basic principles of Quality Assurance concepts, including:
- international standards, e.g. ISO 9000:2000 series
- HACCP
- right first time
- total quality management
- auditing
- environmental control
- product safety
The basic principles and purpose of standards for laboratory practice, e.g. NAMAS

Syllabus 2013 23
 3.5.2 Hygiene
The relevance of the nature of process plant internal surfaces
The relevance of pipework and fittings design
The principles of in-place cleaning (CIP)
The basic principles of design and operation of a CIP system for packaging plant
The range and main constituents of commercially available cleansing agents:
- detergents
- sterilising agents
- typical usages on stainless steel
- hot
- cold
- typical usages on other plant materials
Detection and quantification of residual surface contamination:
- visual inspection
- rinse sampling
- swab sampling
- media plating applications
- forcing tests
- bioluminescence testing

3.5.3 Product and package analysis

The basic concepts applied to interpretation of analytical data:
- sampling error
- accuracy & precision
- repeatability (r)
- reproducibility (R)
- specification ranges (tolerances)
- simple probability calculations:
- normal distributions
- standard deviation
- variance
The relevance of inter-laboratory collaborative checks
The basic principles of analytical and on-line measurement techniques for:
- original gravity - pH
- alcohol content - Invertase test
- dissolved carbon dioxide - in package shelf life measurement, actual and predictive
- dissolved oxygen - checking the crowning operation
- dissolved nitrogen - measurement of seams
- Colour - foreign body detection
- bitterness - in package volume
- specific gravity

24 IBD Diploma in Brewing

SECTIONS 3A AND 3B PACKAGING TECHNOLOGY AND PROCESS TECHNOLOGY

UNIT 3.6 PROCESS GASES

CANDIDATES MUST NOTE THAT THIS UNIT MAY BE EXAMINED UNDER SECTION A (PACKAGING TECHNOLOGY) AND
SECTION B (PROCESS TECHNOLOGY)

3.6.1 Principal Properties of CO2, N2, O2 and Compressed Air as Process Gases
Typical brewery applications
- blanketing/ O2 exclusion
- carbonation adjustment
- oxygenation/ aeration
- nitrogenation and use of CO2 and N2 mixtures
- dispense systems
Purity requirements related to beer quality

3.6.2 Use of Gas Laws

Equations relating to pressure, temperature, volume and density using the perfect gas laws (Boyle’s, Charles/
Gay Lussac’s laws)
Concept of “Standard Conditions” (STP, NTP, etc.)
Universal gas law and gas constant
Concept of molar volume
Dalton’s law of partial pressures
Calculations involving gas laws

3.6.3 Gas Solubility

Concept of gas/liquid equilibrium – Henry’s law (and as applied to gas mixtures)
Dependence of gas/liquid solubility on temperature
Molar fraction/ Molar ratio
Effects of hydrostatic head
Definition of supersaturation and how it occurs in beer
- its effects and threats to beer quality:
- in the brewery
- in the retail outlet
- to the consumer
Calculations of gas equilibrium conditions in process vessels and pasteurisers

3.6.4 Gas Dissolution

The principles of dissolving gases in liquids
Typical equipment for measurement and control
Dissolved gas adjustment
Effects of pressure and temperature on carbonation level during storage of beer

3.6.5 CO2 Recovery Methods

Quality specifications
Theoretical amount recoverable from a fermentation
Typical recovery process areas and rates
Typical contaminants
Recovery collection and pre-treatment
Simple liquefaction plants
Liquid distillation systems
Liquid CO2 storage conditions and vaporisation methods (including secondary
refrigerants for energy saving)
Health and safety aspects

Syllabus 2013 25
 3.6.6 Oxygen and Compressed Air
Oxygen and air specifications
Oxygen supply/ storage/ vaporisatiion
Compressed air treatment
Oxygenation methods (including CIP/ sterilisation facilities)
Health and safety aspects

3.6.7 Nitrogen
Nitrogen specifications
Supply/ storage/ vaporisation
Awareness of on-site generation methods (pressure swing/ membrane/cryogenic)
Health and safety aspects

3.6.8 De-aeration
Methods of water de-aeration using steam, vacuum, CO2 and N2

SECTIONS 3B PROCESS TECHNOLOGY

UNIT 3.7 FLUID FLOW

3.7.1 Forms of Fluid and Fluid Energy

Newtonian and non-Newtonian fluids (with brewery examples)
Definition of viscosity
Mass flow and conservation of mass
Components of fluid energy (pressure, kinetic and potential)
Conservation of energy
Principle of energy interchangeability, Bernoulli equation (brewery examples)
Concept of “head” as a measure of pressure

3.7.2 Properties of Moving Fluids

Laminar and turbulent flow
- their relevance in brewing
- the relevance of Reynolds number (as a measure of turbulence)
Velocity profiles in pipes (with increasing Reynold’s number)
Hydraulic mean diameter for non-circular channels
Mean and maximum velocities in pipes (relevance in breweries)

3.7.3 Friction Loss

Pressure loss in pipes
- friction factors
- pipe roughness (typical data)
Pressure losses in pipes using Moody diagram
Pressure losses in fittings using the “equivalent pipe diameters” and “velocity heads” methods

3.7.4 Pumps
Centrifugal pumps - principles of operation
- impellor designs
- materials of construction for different applications
- hygienic considerations
- shaft seal, flushing and control
- self-priming pumps for CIP
- multistage pumps for high pressure applications
- pump characteristics

26 IBD Diploma in Brewing

 - effect of speed variation
- flow control and “soft start”
- typical applications
Positive displacement pumps - principles of operation
- pump characteristics
- need for pressure relief
- pump types, including materials of construction and hygienic considerations
- Rotary pumps (lobe, progressive capacity, “mono”, peristaltic)
- Reciprocating (piston, diaphragm)
- blending pumps
- CIP
- flow control
- typical applications

3.7.5 System Design

Evaluation of total pressure requirements of a system
- relevance of the operating point
- effect of changes to the system on the operating point
- special considerations for vessel filling

3.7.6 Cavitation and Net Positive Suction Head

Causes and effects of cavitation
Factors which promote or hinder cavitation
The terms NPSH required and NPSH available
The particular problems in breweries and techniques for overcoming problems

3.7.7 Valves
The basic design features, respective merits and typical brewery applications of the following types of valves:
- butterfly
- ball
- gate
- non-return
- pressure and vacuum relief
- double seat (mix-proof)
- control valves (with various plug designs)
Concept of double block and bleed for protection
Sampling systems

UNIT 3.8 PRINCIPLES OF HEAT TRANSFER

3.8.1 Forms of Heat Energy

Definition of Specific Heat
Concept of Latent Heat and exothermic heat as material properties
Examples of specific heat, latent heat and exothermic heat in the brewery
Calculations of energy change associated with these forms of energy

3.8.2 Heat Transfer Mechanisms

Conduction
Convection
Radiation
Typical brewery examples

Syllabus 2013 27
 3.8.3 Conduction
Mechanism of conduction
Concept of Themal Conductivity as a material property
- examples of thermal conductivity of materials (good and poor)
Calculation of heat transfer through a flat slab of material (single and multi-layer systems)
- special consideration for thick circular sections (such as insulated pipes)
Effect of fouling and scaling

3.8.4 Convection
Mechanism of convection with the sub classifications of “Natural” and “Forced”
Concept of heat transfer across a film layer and the benefit of high turbulence
Concept of the “Film Heat Transfer” coefficient (h) to be treated as a “conductivity factor”
Reference to calculation methods and influence of velocity (NB Candidates will not be asked to calculate the
film heat transfer coefficient)
The Plate Heat Exchanger as a good example of forced convection with high velocity/ turbulence

3.8.5 Multi-component Barrier

Heat transfer through a multi-component barrier (e.g. across a plate heat exchanger plate with fouling layers,
film coefficients and conductivity for the plate and fouling layers)
Calculation of the overall heat transfer coefficient “U value” and calculation of heat transfer in a typical
composite system

3.8.6 Boiling and Condensation

Boiling and condensation heat transfer as an extension to Convection with its relevance to brewing processes
Nucleate boiling and film boiling with reference to Kettles/ Coppers
Effect of stainless steel and copper surface properties (“wetability”) on the 2 mechanisms

3.8.7 Radiation
Brief explanation of radiation
- basic Stefan-Boltzmann equation
- emissivity of various surfaces
- areas where radiant heat transfer is relevant in the brewery (e.g. heat losses from vessels)
Sol-air temperatures as a meanss of calculation for heat gain of buildings and external equipment
Radiant heat loss reduction

3.8.8 Heat Exchanger Sizing

Concept of the heat balance and heat transfer across a temperature gradient
Concept and calculation of LMTD with likely differences with “arithmetic mean”
Co- and counter-current flow in a heat exchanger (with some example applications)

3.8.9 Plate Heat Exchanger (PHE) Designs

Construction of a plate heat exchanger, its components and configuration
Function of plate patterns
Typical heat transfer coefficients
The importance of the sealing gaskets and the “grid” or “divider” plates
Parallel and series passes to match flow and heat recovery requirements
Typical approach temperatures in duties, such as wort cooloing
Calculations of a typical heat exchanger area and numbers of plates

3.8.10 Specific PHE Applications

Use of PHE in:
- wort cooling (both single and 2 stage)
- beer chilling

28 IBD Diploma in Brewing

 - pasteurisaton
- importance of fouling/ scaling problems
- CIP techniques
- process and instrumentation arrangement
- leakage protection

3.8.11 Jacketted Vessels

Heat transfer in jacketted vessels with steam or liquid (e.g. secondary refrigerants) in the jackets
Fouling and cleaning
Effect of non-condensable in the jacket
Heat transfer in a fermenting vessel
- changes in heat transfer coefficient
- effects of the inversion temperature
- effects of aspect ratio

3.8.12 Shell and Tube Applications

Shell and tube heat exchanger configuration
Heat transfer in wort boilers (calandria)

3.8.13 Insulation
Function of insulation
Choice of materials based on temperature, duty, safety and environmental points
The function of the vapour barrier for cold duties
Protection of stainless steel surfaces against possible chloride attack
External protection of insulation material
Typical multiple layer insulation systems

UNIT 3.9 STEAM

3.9.1 Properties
Reasons for using steam
Physical properties of water in its states
- Temperature-Energy relationship as illustrated in the Mollier chart
- Steam tables
- Specific heat of liquid water
- Latent heat of vaporisation
- Definition of terms describing steam quality and their position on the
- Mollier chart
Clean steam
Calculation involving change of energy to a steam system

3.9.2 Steam Systems

Pipe sizes, arrangements and design velocities
Insulation
Steam traps
Control valves, reducing valves, relief valves
Legal implications in having a properly designed, safe system with the correct protection measures

UNIT 3.10 Refrigeration

3.10.1 Definition of Refrigeration

Definitions of refrigeration
Primary and secondary refrigeration circuits

Syllabus 2013 29
 3.10.2 Refrigeration Theory
Concept of pressure/ temperature equilibrium in relation to the refrigeration process
Basic elements of a Vapour Compression refrigeration cycle
- Function of:
- Evaporator
- Compressor
- Condenser
- Expansion valve

3.10.3 Refrigeration Practice

Refrigeration cycle described on the Mollier chart
- Terms:
- superheated
- sub-cooled
- isenthalpic
- isobaric
Coefficient of Performance (COP)
Calculation of performance using Mollier chart
Typical manufacturers’ performance curves
Measures to improve output and COP
Effects of “parasitic” loads

3.10.4 Compressor Types

Descriptions of Reciprocating compressors and Screw compressors
- Advantages and disadvantages
- Capacity ranges
- Controllability

3.10.5 Condensers
Descriptions of:
- Dry, “air-fin” condensers
- Wet, evaporative condensers
- Wet, cooling tower and condenser
Advantages and disadvantages
Power requirements
Water requirements
Legionella precautions

3.10.6 Evaporator and Expansion Device

Descriptions of different types:
- Direct expansion with thermostat valve
- Flooded types with level control valves
Advantages and disadvantages
Controllability

3.10.7 Primary Refrigerants

Description of purpose, design considerations and choice
Safety and Environmental:
- Legislation
- Global warming potential
- Ozone depletion potential
Types available:
- CFC, HCFC, HFC, hydrocarbons, inorganic

30 IBD Diploma in Brewing

 - Significance of ASHRAE “R” designation
- Relative costs
- Physical and chemical properties, oil compatibility

3.10.8 Secondary Refrigerants

Description of purpose, design considerations and choice
Physical properties:
- freezing point
- viscosity
- flammability
Chemical properties:
- compatibility with materials of construction
Safety and Environmental:
- leak protection
- pressure controls
- management controls

3.10.9 Applications in a Brewery

Reasons for use
Wort coolers - single and 2 stage
- typical system with control system
Fermenter cooling
- typical arrangement with control system
Green beer chillers
- application of co-current to minimise freezing risk
- typical control system
3-stage plate pasteuriser
- arrangement with control system

UNIT 3.11 MATERIALS OF CONSTRUCTION

3.11.1 Classification
Descriptions of:
- Metals
- Plastics - thermoplastics and thermosetting plastics
- Glass
- Other materials

3.11.2 Properties to be Considered

Tensile and compressive strengths
Compatibility with process conditions
Ease of fabrication
Finish , where important (such as internal finish from hygiene aspect)
Availability and relative costs

3.11.3 Duties
Process:
- Water (including softened water)
- Raw materials
- Wort
- Beer
- CIP
- Storage vessels

Syllabus 2013 31
 Utilities:
- Water
- Liquid and gaseous CO2
- Air
- Refrigeration

3.11.4 Process Applications

Metals:
- Copper
- Stainless steel
- Mild steel
- Galvanised steel
- Cast iron
- Aluminium
Other materials – brief reference to:
- Wood
- Concrete
- Stone
Stainless steels
- Types, with approximate compositions
- Properties, such as thermal conductivity
- Fabrication and relative costs
- Limitations, corrosion
- Applications
Use of plastics and glass
- Food compatibility
- Applications in the brewery
- Linings/ coatings

3.11.5 Surface Finishes

Surface finishes for:
- Brewhouses
- Fermentation rooms
- Process areas
- Yeast rooms
- Other key areas

UNIT 3.12 PROCESS CONTROL AND INSTRUMENTATION

3.12.1 Aims
Definition of the aims of process control

3.12.2 Basic Control Elements

Definitions and descriptions of;
- Sensors
- Controllers
- Actuators
- The Process

3.12.3 Basic On/ Off Control

Descriptions of:
- Timers
- Thermostats

32 IBD Diploma in Brewing

 - Pressure switches
- Level switches
- Proximity detectors
- Position switches
- Deadband

3.12.4 Sequence Control

Description of Programmable Logic Controller (PLC)
- For example, to control a batching sequence

3.12.5 Aim of Process Control

Continuous or modulating control
“Feedback” control
Open loop and closed loop control
Difference between continuous and on/ off control

3.12.6 Principles of Process Control

Concepts of controlled, measured and manipulated variables:
Input to controller
Function of Set-point
Characteristics of Proportional output (P)
Characteristics of Integral output (I)
Characteristics of derivative output (D)
Combinations of outputs (P, P + I, P + I + D)
The ideal controller response

3.12.7 Control Arrangements

Concepts of: feed back, feed forward, cascade and ratio controls
Advantages and disadvantages of each
Typical brewery applications

3.12.8 Typical Control Systems

Descriptions of:
- Self acting systems
- Pneumatic
- Electronic to pneumatic conversion
- Electronic 4 mA to 20 mA analogue
- Distributed digital systems

3.12.9 Sensors
Factors determining the choice of sensors:
- Food/ brewery compatibility and special requirements
- Calibration and servicing requirements
Description of some typical conventional sensors for:
- Pressure
- Volume flow
- Temperature
- Mass flow
- Level
- Vessel contents
Description of some typical analytical sensors for the brewing industry:
- CO2
- O2

Syllabus 2013 33
 - Optical devices
- pH
- Density
- A lcohol content
- Yeast cell viability

3.12.10 Actuation
Descriptions of:
- Pneumatic, including function of positioner
- Electrical
- Electronic (e.g. variable speed drives)

3.12.11 Control System Arrangements

Self-acting controllers (e.g. Spirax)
Individual electronic analogue controls
PLC for multiple sequence controls of batch processes
Small local computer control, to control multiple process control loops
Large digital systems with distributed data highways, incorporting:
- Supervisory Control and Data Acquisition (SCADA)
- Management Information Systems (MIS) for management data
Interlinking of systems
Advantages and disadvantages of each
Comparative costs (i.e. cost per loop)

UNIT 3.0 SI UNITS

Although SI units will not form an examination topic, it is important that all candidates are fully conversant
with their use and of the conventions for writing SI units. Examination questions will use SI units wherever
practicable. The candidates should be familiar with the written form of the IBD preferred form of symbols
and units.

A full list of the IBD preferred form of symbols and units is included as Section 3.0 of the Module 3B Revision
Notes - Process Technology. This covers:
- the principles of SI units
- derived SI units likely to be encountered in brewery applications
- multipliers and prefixes used in SI units
- “Accepted non-SI” units (e.g. ºC, bar, hectolitre)
- Conversion between non-SI and SI units for calculation purposes

34 IBD Diploma in Brewing