Module 3 Section 3A

Unit 3.1
Syllabus Item 3.1.1. Small Pack

Packaging Technology and Process Packaging Technology

Packaging Materials
Understanding of Primary, Secondary and Tertiary Packaging including: The Function Basic Properties, Marketing and Legal Impact Environmental Effects Basic Principles of Manufacture of Glass and Plastic Bottles Cans and Can Ends Crowns Including choice of materials, linings and typical faults Basic Principles of Manufacture of Kegs, Casks and Spears including: Choice of Material Choice of Linings Impact of Materials and Linings on properties of Beer Labelling and Coding Legal Impact Use of Transponders for Tracking

3.1.2. Large Pack

Unit 3.2.

Unit Packaging Operations

Basic principles of design and operation of a returnable or nonreturnable bottling line or a canning line including: Key items of plant utilised Flow diagrams Basic principles of o Design and operation of bottle washer including types of label, label removal and detergents used o Design and operation of a bottle or can rinser o Design, operation and control of a bottle filler and crowner with special reference to oxygen and fill level control o Design, operation and control of a can filler and seamer with special reference to oxygen and fill level control o Types of labelling and coding available o Wet glue labeller operation with special reference to paper and glue types Basic plant features and control procedures, from packaging release tank 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 Basic principles of the additional precautions required for a sterile operation, from sterile filtration or plate (flash) pasteurisation to bottle or can including: Principles of plant cleaning Principles of empty package cleaning Methods of ensuring a sterile fill Methods of closure cleaning Additional laboratory analysis 2

3.2.1. Bottling and Canning Basic Principles

3.2.2. Bottling & Canning Plant Features

3.2.3. Bottling & Canning Sterile Filling

3.2.4. Keg Racking (Filling)

3.2.5. Cask Racking (Filling)

3.2.6. Keg & Cask Racking Plant Features

Basic principles of design, operation and control of combined keg cleaning/filling machines including: Choice of detergent, concentration and temperature Typical regimes for cleaning, sterilising and filling cycles The relative merits of inverted versus upright filling Methods of controlling fill levels Merits of using gases other than CO2 as a top pressure for kegging operations Basic principles of beer preparation, and design, operation and control of a cask cleaning/filling plant including: Beer condition Beer fining Hop product addition Choice of detergent, concentration and temperature Typical regimes for cleaning, sterilising and filling Shive/keystone removal and insertion Basic plant features and control procedures, from packaging release tank through to filled labelled containers, which minimise: Beer dilution Variations in beer CO2 levels O2 pick up Loss of foam potential Particulate matter in the beer Microbiological Contamination

Unit 3.3.

Principles of Sterile Filtration and Pasteurisation

The definition of the term Sterile Filtration Understand the mechanism of filtration Types of filtration available Difference between nominal and absolute rating Filter operation including: Reason for pre-filtration Flow characteristics Integrity Testing CIP/Sterilisation The definition of Pasteurisation and a pasteurisation unit (PU) The relationship between time and temperature on lethal rate The effect of pasteurisation on different organisms Simple calculations on the relationship between pressure, temperature and CO2 content The basic principles of design, operation and control of a plate pasteuriser for bright beer of 3.0 to 6.0 g/l (1.5 to 3.0 vols) including: The definition of percentage regeneration Typical values for: o Time, temperature and PUs applied o Operating pressures o Acceptable initial microbiological load Principle effects on beer quality during pasteurisation The basic principles of operation and control of a modulated flow flash pasteuriser The basic principles of design, operation and control of an inpackage pasteuriser including: A typical time:temperature regime Typical PU values applied Control methods used to minimise over-pasteurisation Principle effects on beer quality during pasteurisation

3.3.1. Sterile Filtration

3.3.2. Pasteurisation Theory

3.3.3. Plate (Flash) Pasteurisation

3.3.4. In-Package (Tunnel) Pasteuriser

Unit 3.4.

Packaging Line Design and Performance

Basic understanding of packaging line design theory including: V graph Advantages and disadvantages of straight line and U shaped layouts Balance and accumulation Use of variable speed equipment Materials handling Rejects and waste handling Principles of packaging line performance measures which detail the impact on overall performance of: Plant efficiency Mechanical downtime Planned downtime including, cleaning and maintenance Unplanned downtime including unavailability of plant, product, materials and services Basic understanding of systems used to measure performance including: MIS (Management Information System LIS (Line Information System)

3.4.1. Packaging Line Design Theory

3.4.2. Packaging Performance

3.4.3. Systems

Unit 3.5.

Quality
The difference between Quality Control and Quality Assurance The basic principles of Quality Assurance concepts, including: International standards eg ISO 9000 series HACCP RFT (Right First Time) TQM (Total Quality Management) The basic principles and purpose of standards for laboratory practice eg NAMAS The relevance of the nature of process plant surfaces The relevance of pipe fittings and design The principles of CIP (Cleaning InPlace) 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 PCR (Polymerised Chain Reaction) Test The basic concepts applied to interpretation of analytical data Sampling error Accuracy and precision Repeatability (r) Reproducibility (R) Specification ranges (tolerances) 6

3.5.1. Quality Management

3.5.2. Hygiene

3.5.3. Product and Package Analysis

3.5.3. Product and Package Analysis (Cont)

Simple probability equations: o Normal distribution o Standard deviation o Variance The relevance of inter-laboratory collaborative checks The basic principles of analytical and on-line measurement techniques for: Original gravity Alcohol content Dissolved CO2 Dissolved O2 Dissolved N2 Colour Bitterness Specific gravity pH Invertase test In-package volume In-package shelf measurement, actual and predictive Crown crimp checks Seaming checks Foreign body detection Label Dress