PROCEDURE FOR

FERMENTATION PROCESS
FOLLOW UP

Contents

1. REVISION HISTORY 2
2. INTRODUCTION AND OBJECTIVE 2
3. SCOPE 2
4. DEFINITIONS 2
5. REQUIREMENTS 3
6. IMPLEMENTATION SCHEDULE 7
7. REFERENCE TO OTHER DOCUMENTS 7

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1. REVISION HISTORY
1.1.
Issue Change description Status Author Date
1 Document created In Milos Stojanovic Mar 2021
process

2. INTRODUCTION AND OBJECTIVE

2.1. The objective of this procedure is to define the mandatory requirements and activities
for batch Cellar Operations and enable operators to achieve the right Product Quality
and to manufacture consistent and high quality products that are safe for consumers.

3. SCOPE
3.1. This procedure is mandatory for production of all beer types in ALFA S.A. Specific
process phases and brand parameters are defined in the recipe of each brand and
should be followed up and adhered to.

4. DEFINITIONS
4.1. The following definitions apply:
Term Definition
Fermentation Fermentation is the process period from the start of yeast
pitching until start of lagering when the yeast converts the
majority of fermentable sugars.
Green beer Beer which has completed primary fermentation.
Pitching yeast Yeast dosed at the start of fermentation, selected to meet the
requirements of this standard.
Pitching rate The pitching rate is the amount of yeast to be added to one
hectolitre of cold wort expressed in grams of yeast at 100 %
consistency.
Fermentation speed The fermentation speed expressed in °P (wt)/24 hrs is
calculated as follows:
 The difference in apparent extract from the start of filling
up to and including the fifth day of fermentation divided by
five, unless specified otherwise in the Recipe.
RUH The RUH period starts after the fermentation.
The RUH period begins when the AE = 3.2 °P and the
temperature equal to 13.5 °C condition is fulfilled.
Deep cooling After the RUH, the beer is cooled down to the cold storage
(maturation) temperature. Deep cooling time is the time
from start deep cooling until start maturation.
Maturation Maturation time is the time from start maturation time till
start filtration.
Lagering Lagering is the process period in which the beer is matured.
The lagering consists of a RUH period and a cold storage
(maturation) period. The remaining fermentable sugars after
fermentation are converted and the beer is matured. In
between the RUH and the cold storage, the beer is cooled
down (“deep cooling”) to the cold storage (maturation)

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 temperature.
Surplus yeast Surplus yeast is the yeast after harvest or purge, which is not
for further use in the brewery.
Generation Yeast, which is harvested from the propagation step in
fermentation tank, is referred to as “Generation 1” yeast.
VDK The most well-known Vicinal Diketone in beer is Diacetyl.
This has a very low flavour threshold 0.05– 0.07 ppm.
Together with a related compound, 2,3 pentanedione, with
off-flavour threshold of 1 mg/l, it gives beer a “toffee”,
“butterscotch” flavour. This is one of the most common off
flavour defects in lager, although it is sometimes a desirable
flavour. Diacetyl is removed by yeast, late in the
fermentation phase.
Apparent extract Unfermented extract expressed in °P
(Ea)
Original extract Original content of extract in wort after brewing expressed
(Eo) in °P
Yeast consistency The consistency of yeast expressed in per cents by weight
Yeast dead cells Content of dead cells in yeast expressed in per cent
WLN WLN medium is used to gain a general insight into the
hygienic conditions of the production departments
WLD When actidione is added to WLD media to suppress the
brewing yeast, we refer to the medium as WLD. It is used to
detect wild yeast in beer or rinsing water.
IBU International Bitterness Unit
EBC European Brewery Convention (unit for colour)

5. REQUIEREMENTS

5.1. Safety, Health and Environment (SHE)

Occupational Safety Aspects Mandatory requirements
Working environment Always follow all safety instructions indicated at
the working place. Use the appropriate Personal
Protective Equipment (PPE).
Handling equipment and Keep work areas clean and uncluttered to avoid
instruments spills, glassware breakage and cross-
contamination.
Working area tidiness Work carefully, without rushing or running. Rinse
the floors with water and keep clean from
residues of wort or beer.

5.2. Hygiene Requirements

Hygiene Aspects Mandatory requirements
Build-up of fouling, deposits and Must be prevented by:
microbial contamination in - Regular rinsing with water after
fermentation area due to drainage of sample is taken
beer to the floor while sample taking - Regular weekly detailed

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 cleaning with usage of chemicals
and special tools (brushes)
Build-up of fouling, deposits and Must be prevented by:
microbial contamination inside of the - Good through rinsing with water
measuring burette after each usage

5.3. Quality Requirements

Quality Aspects Reference
Original extract of wort mix 14.3 ± 0.3 °P
Fermentation speed (120h after start of 1.9 ± 0.2 °P/24 h
filling)
pH of wort mix 5.2 ± 0.1
pH at the end of fermentation 4.3 ± 0.1
Filling time 27 h ± 60 ‘
Alcohol after fermentation and deep 6.5 ± 0.2 % v/v
cooling
VDK after fermentation and deep < 0.07 mg/l
cooling
Colour after fermentation and deep 12.75 ± 1.25 EBC
cooling
Bitterness after fermentation and deep 30 ± 3 IBU
cooling
Cells after fermentation and deep < 5 x 106
cooling
Yeast consistency at pitching 40% ÷ 60 %
Maximum yeast generations 5
Maximum dead cells 5%
Maximum yeast age 72 h
Apparent extract to start wait for RUH 6.8 ± 0.2 %
Apparent extract after fermentation and 2.55 ÷ 0.15 °P
deep cooling
Top pressure during fermentation and 0.15 ± 0.05 bar
lagering
Temperature during fermentation 10.5 ± 0.5 °C
Minimum RUH temperature 13.5 °C
Maturation temperature -1 ± 0 °C
5.4. Process description
5.4.1. Fermentation process follow up starts immediately after start of first wort
transfer and filling of the fermentation tank (FMT). Control room operator that
starts FMT filling is responsible for issuing (printing and filling of required
yellow fields) the document Fermentation process follow up [1]. Operator that
finishes filling of FMT is responsible to fill in required (green) fields.
5.4.2. After 48 hours from end of filling time, sample for microbiology should be
taken. If this time is in the first shift, sample is being taken by the
microbiologists. In second and third shifts, sample is being taken by the CR

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 Operator. During the taking of sample, all instructions for proper hygienic
sampling should be respected and all necessary information’s recorder in
designated notebook.
5.4.3. From that moment on, and for the first three days, FMT is being measured for
apparent extract and pH by control room operator in first shift. Records are kept
in the Fermentation process follow up [1] list (light blue fields).
5.4.4. From the fourth day FMT is being measured for Ea by operator in each shift
until start of RUH phase.
5.4.5. During the fermentation process, pH is being measured only in first shift and
recorded in the list. Measurement stops after 20 days of process time.
5.4.6. On the fifth day after start of filling (exactly 120 hours after) FMT is to be
measured for Ea and fermentation speed to be calculated. It is responsibility of
each operator to follow up in his shift if some of the FMT’s are supposed to be
measured for Ea and fermentation speed calculation. All data is to be recorded in
the follow up list.
5.4.7. When Ea reaches level of 6.8 ± 0.2 % FMT should be moved to the step
“Waiting for RUH”. Therefore, operators should closely follow up status of each
FMT, and sometimes might be necessary to measure Ea more than once in the
shift in order to be able to determine the right moment for step change. Each
operator is responsible to autonomously determine the required number of
measurements in order to be able to define the right moment of step change.
5.4.8. The start of the Ruh is defined by fulfilment of these two conditions:
5.4.8.1. The AE has reached 3.2 °P and
5.4.8.2. The temperature (top) is ≥ 13.5°C
5.4.9. Yeast harvest should be done 26 ± 2 hours after start of RUH. Each operator
is responsible in his shift to autonomously determine the right moment for yeast
harvest. All available yeast must be harvested from a FMT. The harvest ends if
the consistency of the yeast is below the minimal consistency.
5.4.10. On the 10th day after filling of FMT, sample should be taken for analysis of
VDK. It is responsibility of the operator in first shift to take the sample and
request from laboratory technicians to perform the analysis. The sample should
be provided to laboratory as early as possible in the first shift so that results will
be available before the end of the first shift at the same day.
5.4.11. If the level of VDK in the FMT is below required and minimum process time
for FMT after end of filling of 10,5 days has passed, deep cooling can start.
Control room operators are responsible to autonomously determine if the
conditions are met and also pass all necessary information’s to their colleagues
in other shift in order for the fermentation process to be followed up correctly.
5.4.12. If level of VDK is not low enough as required, RUH time is prolonged and
measurement repeated after minimum 12 hours, or until it reaches required
value.
5.4.13. When deep cooling starts, FMT is again being measured once per day, until
the total process time of 20 days.
5.4.14. After start of deep cooling step, and when temperature (below) reaches 2 °C
yeast purge should be performed. FMT will automatically enter the step “Yeast
purge” and wait for the process of purging be initiated by operator. This process
should not be delayed and should be performed as soon as possible, when the
yeast harvest line is available. When yeast purge is done, FMT should be moved

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 to the step “Maturation”. Operators that are finishing the yeast purge activity are
responsible for timely step change. Amount of purged yeast should be recorded
in Fermentation process follow up list [1]
5.4.15. After 48 hours in deep cooling, FMT is being measured by laboratory
technician for following parameters: Alcohol, Original gravity, Colour,
Bitterness and Yeast total cells count.
5.4.16. Control room operators are responsible to follow the process and determine
the right moment when 48 hours have passed and temperature of beer is around
0 ° C, take sample to be measured and deliver it to laboratory technicians.
Sample should be provided to the laboratory on timely manner and in the right
quantity of 1 litter.
5.4.17. Records of this analysis are also being kept in the same list, and it is
responsibility of the operator in the first shift after results are available to record
them.
5.4.18. All other activities like yeast harvest, yeast purge, filtration etc. are being
recorded in the same list by the operator that have performed (started or
finished) or being present during (filtration) the activity.
5.4.19. Information’s which are not immediately available when FMT is being filled
in (like microbiology results of the CIP) should be filled in by the operator in the
first shift when results become available. Usually, results are available on the 4th
day after CIP is done. Results can be checked at the electronic document which
is kept at share folder under the following address: \\dellsp\BrewData\7.
Microbiology\Microbiology - Samples and Results
5.4.20. The long term history of fermentation process is being recorded in the
documents called “Fermentation protocols” [10]. This are electronic Excel files,
which are kept on shared folder, and they should be updated on daily basis by
members of the Brewing management team. Control room operators may also
use this records for their purpose of process follow up, history check up and all
other information related activities which they find useful or needed in their day
to day operations.

5.5. Process Reliability / Reproducibility / Responsibility

5.5.1. To produce high quality beer efficiently and consistently, the “First Time
Right” (FTR) parameters must be monitored and controlled. The definition,
calculation and targets of the relevant Fermentation FTR parameters are defined
in the Quality Assurance Standard: First Time Right Definitions and
Calculations [2]
5.5.2. Daily monitoring and control of process parameters is important for
achievement of the required FTR parameters. Therefore, proper process control
by each operator and in each shift is essential, as well as transparency in timely
and in full communication between shifts and all operators and their superiors.
5.5.3. It is responsibility of brewing management team to daily monitor and support
required activities by:
5.5.3.1. Control if the tasks are being done on time and in full
5.5.3.2. Provide feedback and guidelines if some of the tasks are not being
done correctly
5.5.3.3. Daily work on process standardisation and improvement

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 5.5.3.4. Monitor and evaluate performance of operators and identify gaps in
skills and knowledge
5.5.3.5. Prepare and revise related standards, procedures and instructions
(OPL’s and SOP’s) and perform trainings of the operators in order to close
identified gaps

6. IMPLEMENTATION SCHEDULE
6.1. This procedure will be implemented in March 2021, and fully applicable from April
2021.

7. REFERENCE TO OTHER DOCUMENTS

[1] – Fermentation process follow up list
[2] – HMESC 01.41.02.302 First Time Right Definitions and Calculations
[3] – Elbar Lager Basic Recipe
[4] – 0HMESC 2.32.25.000 Yeast Management, Fermentation and Lagering
Operations Standard
[5] – HMESC 02.32.26.000 Yeast Management, Fermentation & Lagering
Operations Handbook
[6] – HMESC 023225.002 Yeast Propagation and Management W 34-70
[7] – HMESC 02.32.25.106 Yeast Management W 34-70
[8] – OPL_0073_Apparent Extract measurement with saccharometer
[9] – OPL_0074_Ea reading with saccharometer
[10] – Fermentation protocols

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 I have read and understood this document. Information’s provided have been made
clear to me, and all questions or points which I have not entirely understood by
reading this document, have been explained to me by members of the brewery
management team. I am also familiar with other documents on which this procedure
is referring to.
Activities like different analysis which should be performed are clear to me and I
have been informed, trained and given the opportunity to practically perform such
analysis under the supervision of the more qualified colleague or someone from the
management team.

I have fully understood my described responsibilities, and I feel confident in

performing activities which are described and related to may line of work, duty and
position.

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