THE NEW SANITATION SOLUTION FOR BREWERIES
 
FAST, GREEN AND LOW-COST SANITATION FOR BREWERS AT THE FOREFRONT OF TECHNOLOGY

 
BREWERY SANITATION AND DISINFECTION

Breweries are an energy intensive, time consuming and water demanding industry. There are many aspects in brewery operations that can improve profitability and the environmental footprint, and ozone technology can be used in all the following:
• Reducing energy costs
• Handling, storage and administration of chemicals in cleaning and disinfection
• Prolonging the brewing equipment life time
• Reduce production down-time
• Minimizing water consumption

 
 
OVERVIEW OF OZONE

Ozone is the most efficient disinfection agent available and replaces traditional chemicals such as hypochlorite, peracetic acid (PAA) and hydrogen peroxide. It offers at least 20 times higher microbial inactivation potential which means that both concentration and disinfection time can be significantly reduced and is very gentle on materials. Ozone is produced in-situ and on demand only and utilizes oxygen as its only raw material. After use it quickly and naturally decomposes into oxygen, leaving no chemical byproducts. Ozone cannot and should not be stored which significantly reduces storage needs at the brewery.

Watch the introduction video below for brewery sanitation for fermentation tanks, filling machines and other process equipment.

 
OZONE APPLICATIONS IN BREWERIES AND BEVERAGE PRODUCTION
OZONE DISINFECTION OF FERMENTATION AND LAGERING (MATURATION) TANKS

Ozone technology can be used in-lieu of disinfection chemicals and integrated into a current Clean-in-Place (CIP) system for sanitation of all brewery process equipment. Fermentation and lager tanks cleaning and sanitation cycles can be shortened by up to 30 minutes per CIP. Ozone is a perfect replacement of hot water disinfection which avoids frequent heat expansion of pipes, joints and tank material. Using ozone as a part of CIP of such process equipment also sanitizes pipes effectively. Since no by-products are left in the system, final rinse can be avoided, saving water and time.

FILLING MACHINES

All components of the filling line can be disinfected with ozone as a part of the CIP cycle. In addition, it can be used for bottle rinsing, especially applicable in mineral water or cider production where bottle rinsing is crucial. Hot water, which is especially common for filling machine sanitation, can be replaced with cold ozone, saving time and energy.

KEG SANITATION

Ozonated water is also suitable for keg filling machines and its CIP system. Ozone replaced steam and hot water in these applications, making it an economically viable application.

AROMA COMPOUNDS REMOVAL

For breweries that produce successive batches of various types of beverages - mixed batches of beer, cider or flavored mineral water - aroma cross contamination may occur. The effective oxidizing characteristics of ozone present a novel way of removing aroma compounds which may otherwise contaminate the finished product.

OPEN SURFACE OZONE SANITATION

Ozonated water is an effective surface sanitizer (also known as COP, clean out of place), which means it can be used for conveyor belts (for example in the filling line) and floor areas in the brewery.

PECTINATUS AND MEGASPHAERA

In recent years, anaerobic bacteria such as various strains of Pectinatus and Megaspaera have emerged as a serious issue in brewery operations and are often found in lagering and fermation tanks and the filling machine. The superior disinfection capacity, as a strong oxidizing agent, of ozone offers elevated peace of mind pertaining to this emerging problem. Read more at our dedicated web page for ozone disinfection!

SUPPLY WATER QUALITY ASSURANCE

Sanitized and clean supply water for industrial use is an issue in food and beverage production in many parts of the world. Ozone is a cost-effective method to sanitize the supply water used for brewing, sanitation of process equipment and plant wide rinsing. Not only does ozone offer the most effective sanitation, it also removes BOD and COD. In addition, it provides ultra-clear water by removing particles and discolorations. Ozone leaves no by-products or taste. It is a perfect alternative to chlorine dioxide sanitation, which is commonly used in large breweries.

 
 

Did you know...
 
 

Ozone is used worldwide, not only in breweries, but also wineries, the food industry and in all kinds of applications where tanks, pipes and process equipment need to be disinfected.

 
 
CLEANING AND SANITATION - OZONE VERSUS CHEMICALS

It is imperative to clean the brewing equipment, such as piping, fermenters and cooling tanks, from residues left by the organic compounds from the fermentation process. In addition to

unwanted particles and compounds that adhere to the inside surface of the equipment, such leftovers enable a proliferation of microorganisms, creating biofilms. This will

inevitably affect the quality of the end product. The table below shows a number of cleaners and sanitizers used to clean brewing equipment today.

 
COMPOUND
APPLICATION
CHALLENGE
Acetic Acid (cleaner) • Very effective copper cleaner • Rinse water should be applied to avoid oxide deposits which may promote bacterial growth
Hypochlorite (sanitizer) • Effective at breaking up organic compounds
• Low cost sanitizer
• Sanitation effect favored by elevated temperatures
• Corrosion may occur, even for stainless steel vessels (SS304 and SS316), especially with hot water
• Copper vessels are easily oxidized, leaving copper in the beer
• May affect the taste of the following brew unless boiled water is used for rinsing
• If system is not cleaned properly, it will lose its sanitizing ability
Ozone (sanitizer) • Can be applied cold, thus reducing energy costs
• Leaves no harmful by-products
• Produced on-site (in-situ) which eliminates chemical handling
• Negligable consumables (power) cost
• Gentle on materials
• No rinsing required
• Mechanical installation
• Should not be mixed with other organic chemicals in order to achieve maximum effects
Sodium/Potassium Hydroxide, Caustic (cleaner) • Very effective detergent and removes organic residues
• Removes scorched surfaces
• Extreme handling caution must be taken to avoid skin and eye damage
• Very corrosive to aluminum and brass
Paracetic Acid, PAA (sanitizer) • Readily available sanitizer agent with minimal by-products
• Relatively low application temperature
• Shelf-life of beer is reduced unless thoroughly rinsed
• Relatively expensive at required applied concentrations
• Smell
Iodophor (sanitizer) • Effective sanitizer
• Not very common the industry anymore
• Handling precautions must be taken due to its skin and eye irritating characteristics
• Stains upon exposure
• May affect flavor
Heat (sanitizer) • Potentially effective but requires a prolonged exposure at high temperature • High operational costs
• Time consuming due to heat up and cool down periods
 
 
THE OZONETECH SOLUTION FOR BREWERY SANITATION

Ozonetech’s Corona Discharge (CD) ozone generators—combined with an oxygen generator— are highly effective and low in power consumption. Ozone is produced in closed system described in the figure to the right. Any ozone left in the reaction tank off-gas is effectively destroyed, leaving no residual ozone in the work environment. The system has a small footprint and is delivered on a EUR-pallet (120 x 80 cm, 47” x 31”).

Ozone or ORP (Oxidation-Reduction Potential) sensors are used to monitor the degree of treatment and determine the active ozone concentration during the complete sanitation phase.

ELIMINATE SANITATION CHEMICALS
Ozone can be used as the sanitation agent to reduce total CIP time, realize water savings and reduce chemical handling and consumption. The figure to the right conceptualizes the benefits of upgrading your current CIP system with an integrated solution from Ozonetech. Read more at our dedicated CIP and process equipment web page.

Not only can disinfection chemical use be avoided, by applying ozone in the pre-rinse phase, caustic cleaning can be enhances which may further reduce chemical consumption.

REPLACE HOT WATER SANITATION WITH OZONE
Many breweries apply hot water to sanitize tanks, filling machines and other process equipment. For hygienically designed systems, ozone presents large energy savings opportunities and achieves 3-log reduction of unwanted bacteria in 10-15 minutes.

Not only can substantial energy savings be realized, equipment life time and maintenance issues are also improved by avoiding frequent mechanical tensions during heating and cooling between CIP-cycles. Annual operational down time can be avoided by up to 300 hrs which increases production capacity.

Don’t hesitate to contact us today if you want to move towards a more environmentally friendly and sustainable technology for your sanitation needs with a novel technology. It will save you time, energy, reduce water consumption and facilitate a leaner production.




Estimated annual savings for large scale, middle size and craft breweries by replacing hot water sanitation with ozone. Calculations are based on 85 deg C hot water sanitation once per day.
 
 

Did you know...
 
 

Once the ozone system is installed, the need to transport raw material is zero.

 
 
IMPROVE YOUR CIP, ENSURE FEED WATER QUALITY

It’s time to abandon old routines. When sustainability and green technologies are accepted as guiding principles in most industries, why not make the move?
There is much to gain, not just money.

We offer a faster and more effective solution to sanitize water and process equipment for breweries of any size. Our RENA Water Solutions are turn-key ozone systems, easy to install and operate for the complete disinfection needs of your facility.

SIMPLE IMPLEMENTATION
The systems are designed with integrated hydraulic connections. They can be installed both in existing piping and to water tanks. Ozone is efficiently dissolved into the water at

maximum 1 ppm concentrations, still allowing for shorter sanitation cycles compared to disinfection chemicals such as peracetic acid, hypochlorite or hot water. All systems come with integrated controls and safety features for reliable and safe use. Installation is simple, for both existing and new breweries.

NO RAW MATERIALS TO BUY OR HANDLE
Using our ozone systems in your cleaning and sanitation program eliminates handling of hazardous disinfection chemicals. Ozone is produced instantly on site and on demand.

We use natural ambient air to produce oxygen which is then used to produce ozone. This makes our methods environmentally friendly and significantly improves the health and safety

aspects of your production. Each ozone sanitation cycle only consumes 0.3 kWh for a craft brewery and less than 1 kWh for a large facility.

KEY BENEFITS
• Ensure 100% bacteria-free feed water without chemicals
• Maximum 1 ppm dissolved ozone concentration
• One-touch start-stop operation
• Avoid heat and chemical handling
 
 
SAVE TIME, WATER AND MONEY

NO SANITATION CHEMICALS NEEDED
Ozone does not leave any chemical residues. There is no need for water rinse after disinfection is complete. Cleaning and sanitation is a major water consumer, and any brewery can save up to 10% of the total water consumption. And equally important, all sanitation chemicals can be eliminated. Hot water can be replaced by cold ozone sanitation, reducing energy costs significantly.

DISINFECT IN FIVE MINUTES WITH A TOUCH OF A BUTTON
Ozone is the most effective disinfection agent commercially available. It’s up to 3,000 times more effective than hypochlorite and peracetic acid. We exceed required microbial kill rates quicker and at only 1 ppm concentration compared to other disinfection chemicals. You will be ensured bacteria free process water and equipment in a matter of minutes. Just press the button.

The graph to the right shows annual savings for chemicals, water and energy per brewery capacity (USD)

Swap to ozone. It will instantly reduce your water cost, energy cost, chemical cost, environmental impact and increase the production uptime.

 
 
READ MORE
 


GREBBESTAD BREWERY UPGRADED TO OZONE SANITATION
 
NO CHEMICALS AND A SAFER WORKING ENVIRONMENT
 

 
GREBBESTAD BREWERY

Grebbestad is not just a favorite among domestic and international tourists, it’s also Sweden’s oldest microbrewery. The facility brews several popular beers such as India Pale Lager, Saison and the Swedish classic Christmas holiday drink julmust. The brewery, located on the beautiful Swedish west coast, has been using traditional acid and hot water to sanitize the fermentation tanks, filling machine and other process equipment.

They have now upgraded their sanitation routines with Ozonetech’s ozone system resulting in tangible operational benefits and a more gentle environmental footprint.

THE PROBLEM
Ever since the start in 1995, Grebbestad Brewery has been using large amounts of chemicals and hot water to sanitize all process equipment – a necessary procedure to maintain highest possible product quality and prevent product spoilage. It is one of the most water intensive and costly operations during production along with chemical handling issues.

The excellent sanitation potential of ozone presented an attractive solution for the facility.

THE SOLUTION
Together with Ozonetech, the brewery installed a high-performance ozone system which provides effective sanitation and disinfection of frequent clean-in-place operations. Ozonetech’s RENA Vivo

system enables a turn-key sanitation solution in lieu of acid and hot water which has been used since the start.

An intuitive touch-screen, controlling the amount of ozone concentration during disinfection enables on-demand sanitation and leaves no chemical residues. No more handling and administration of hot water or hazardous chemicals.

EVALUATION
The new RENA Vivo A-series high performance ozone system has significantly reduced handling of and associated costs for disinfection chemicals. Water savings have also been realized since chemical residues have been eliminated. Sanitation time has been reduced thanks to the high disinfection capacity of the system.

 

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POPPELS BREWERY REPLACED ACID DISINFECTION
WITH OZONE

 
NO MORE CHEMICAL HANDLING AND A GREENER PROFILE
 

 
POPPELS BREWERY

Poppels Brewery, one of the fastest growing craft breweries in Sweden, has already established a green eco-friendly profile. Now they have taken a significant leap towards lowering their environmental impact even further by implementing ozone technology in their daily operations.

The brewery resides in Partille, Sweden, in top modern facilities to make room for the expanding demand for their beers across the country. The brewery produces many popular beers such as Russian Imperial Stout and Belgian Wit. The team of brewers needed a more sustainable alternative to their chemical consumption and handling. Ozone was chosen to replace the current sanitation agent.

THE PROBLEM
A rapidly increasing production means higher consumables costs as well as handling and storage of chemicals. The brewery staff needed to manage the use of peracetic acid that was routinely applied to disinfect the fermentation tanks and filling machines after each production cycle. Peracetic acid is a common sanitation agent, but requires careful handling and thorough rinsing in process equipment to ensure by-product free beer.

THE SOLUTION
As a joint project with Ozonetech, a high-performance ozone system was implemented in the existing Clean-in-Place system. Ozone has now replaced the acid use. Ozone is produced on demand only and in a safe manner. Aqueous

ozone now circulates in the system following caustic cleaning of the process equipment.

The Ozonetech RENA Vivo A-series is installed in a side-stream connected to the main CIP system. Ozone use for process equipment sanitation requires a high-performance, oxygen fed, and water cooled ozone system with an integrated gas liquid ozone transfer mechanism.

EVALUATION
After ozone sanitation of the fermentation tanks and filling machine, the disinfection results are validated using ATP analysis. The RENA Vivo system delivers results according to the high standards Poppels demand. The brewers now have an acid-free working environment.

 

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Food and Hygiene Ozone Treatment RENA Vivo Brewery sanitation and disinfection