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DFHCompanyConfidentialRevision#

DOGFISH HEAD CRAFT BREWERY

DOC # SB03

Clickheretoenteradate.

SABCO OPERATION AND CIP CREATED BY: Kristen Ewer

Date Created: 1/2/15

Revised Date: Clickheretoenter

text.

PURPOSE:

ThepurposeofthisdocumentistoinstructDogfishcoworkershowtomanuallyoperatetheSABCO/BrewMagicsystemforSmallBatch,aswellashowtoproperlyandeffectivelyCIPthesystembeforeandafteruse.

EQUIPMENT:

• SABCOBrew-Magicbrewsystem• Brewingingredients• Hotwaterhose(inBay4)• Coldwaterdropdownhose• SBGrainMill(inMaltHandling)• Propane• Lighter• Carboy(s)• Carboygear(airlocksandlidsifusingwide-mouthedcarboys)• Bucket(s)• Largespoon• Timer/Clock• Sampletubes• Anton-Parranalyticalinstrument(onbenchtopinlab)• Meshbag(ifneededduringboil)• Iodine(ifwantingtotestmashforsugarconversion)• Wortchillerandwortchillerparts(seeFigure1onpage____)• CIPchemicals(caustic,iodophor)• Electricalextensioncord(yellowoneinSBroom)



• EitherneworoldSABCOkettle(newoneisnotfittedwithafalsebottom,buttheoldoneis,soifyou’dpreferbrewingwithafalsebottominyourkettle,swapoutthenewonefortheoldkettle,whichiskeptinthewoodroom)

PROCEDURES:

NOTE:ThisSOPwillinstructtheusertousetheSABCOmanually,andwillnotgooverhowtoprogramtheelectronicrecipesinMagicSoftorhowtousetheelectronicheaterontheSABCO.Iftheuserwishestoutilizethesefeatures,pleasereadtheBrew-MagicManualforfurtherinstruction.

Soyou’rereadytobrewyourSmallBatchbeer!Youandyourteamhaveshownupforyourbrewday,youallhaveyourproperPPE,ingredients,maybeasnack,sometunes,andarereadytoroll.YoucaneitherbrewinBay4(preferredforproximityofutilities)oroutsidebytheBocceBallcourts(thisSOPwillfocusonBay4functionality).MovetheSABCOsystemawayfromthewallintoBay4,outofthewayofthetourroute(ifbrewingduringtourhours)andplugherin.

1. Let’sgooversomescreenstuffsoyouknowwhatyou’relookingat.Anyscreenwillalwaysincludeanavigationmapatthebottomwhereabluedotwillshowyourcurrentlocation.Thereare4columns;home,recipechecklist,mashandboil.Navigatingleft/rightmovesyouthroughcolumnsandscrollingup/downmovesyouthroughthecolumnwhereyouarecurrentlylocated.ItisimportanttorememberthatwithmanualoperationoftheSABCO,youwon’tusemanyoftheparametersinthecomputer.

2. TheMainMenu- theBrewoptionisformanualuseofthesystem.RecipesandSettingsareformoreintegrateduse(pleaseseeBrew-Magicmanualfortheseoptions).HitBrew!

3. Thisscreenwillpopup- thisisthemainbrewingscreen.

Navigationbar

HitME!



a. Thetopleftisthestatusbaranddescribeswhatthesystemiscurrentlydoing.Here’salistofwhateachstatusmeans:

i. ScrollDowntoStartMash/Boil–nothingishappening,thesystemiswaitingforyoutostart

ii. Pumping–thepumpisonbuttheheatisnotoniii. UseBurner–thepumpisonandyoushoulduseyourgasburnertoheat

thevessel–thisistheheatingoptionyoushouldbeusingiv. Self-Regulating–thepumpisonandtheelectricheatisenabled–this

optionshouldnotbeusedv. TempControlonStandby–thepumpisoffandheatisoffvi. Sensorerror–thecontrollerisnotreceivingausablesignalfromthe

temperaturesensorb. Thetoprighthastwoboxes:

i. Pumpisoff, pumpison

ii. Electricheatingfeatureisdisabled(shouldalwaysbegrey)c. Otherfeatures

i. Yourtemperaturereadoutandtarget.Youcanputinyourtargettemperature,andwhenyou’vehitit,thesystemwillgiveyouanalarm,andyoucaneitherthrottlebackyourheat,orturnofftheburner.

4. Mash/Boilscreen- Scrolldowntogethere.Thisismainlyusedwithprogrammedrecipes,butyoucanrunthetimersforyourconvenience.

5. Settingsscreen- SABCOcanoperateinFahrenheitorCelsius.Youchoose.Anenabledbeeperwillwarnyouwhentemperatureshavebeenreachedortimersinusehaverunout,adisabledbeeperwillstayquiet.



Figure1.SABCO/BrewMagicSmallBatchsystem.Valvesarelabeledinredfont,vesselsinblack.

Valve# ValveDescription1 OutletfromtheBoilKettle2 Three-wayvalvethatdirectswortflowfromtheMashvesselintwopossibledirections

• TotheBoilKettlewhenthevalvehandleisturnedtotheleft(openposition)• Tothepumpwhenthevalvehandleisintheverticalposition(closed,asshown)

3 OutletfromtheHotLiquorTank(HLT).Whenthevalveisopen(horizontalposition),liquidmovestothepump.

4 StopsflowofliquidtoorfromtheMashvessel(shownclosed,intheverticalposition)• WhenopenalongwithValve2closed,liquidcanflowfromtheMashvesseltothepump• WhenopenwithValve3open,HLTwaterflowstoValve2(closed)andcanentertheMash

vessel• WhenclosedwithValve3open,HLTliquidflowstothepumponly

5 RegulatesflowratefromthepumptothetopinletoftheMashvessel6 Drainvalvetoremoveallliquidfromthesystemforcleaningorcoldstorage

ThePump:

• Neverrunthepumpwhenthereisnoliquidthroughit!• Inorderforthispump(magneticdrive,non-suctionpump)tofunctionproperly,there

mustbeliquidrunningthroughitatalltimes.Anyairthatremainsinthepipesorpump



willcausethepumptocavitate,orstopfunctioning.Inordertoavoidpumpcavitation,liquidmustbepassedthroughthepipesandpump,whichiscalledpriming.

Primethepump:followthisprocedurebeforeeachbrewsession,andwithproperpumpingprocedure,thepumpwillremainprimedthroughoutthesession.

1. Donotturnonthepump.2. CloseValves1,2,3,4,5and6.Allof‘em!3. FilltheHLTwithaminimumof12gallonsofwater.Thiscanbeheatedasdesiredfor

brewing.4. OpenValves3,4and5.Watershouldflowintothemashvesselfromthebottomup.5. Whenthewaterlevelreaches1–2inchesoverthetopofthefalsebottom,closeValve

4.6. DonotopenthedrainValve6asitcanpullairintotheplumbing.

Nowthepipesandpumparefloodedwithwater.Thepumpcannowbeturnedonwhenneeded.Whilethepumpisrunning,thefollowingthreethingswillhelpavoidcavitation:

• EitherValve3orValve4mustbefullyopenwithliquidmovingfromthepump.• Openanewliquidsource(Valve3or4)beforeclosingthepreviousliquidsource.• Whilepumping,restrictingflowbyadjustingValve5willnotharmthepump.Fully

closingitwhiletryingtopumpintotheMashvesseltopinletWILLdead-headthepump(makeitpumpwithnowheretogo–notgood!).

Ok,that’sMagicSoftandsomemechanicalstuffataglance–readytobrew?Let’sdoit!

BREWING:(boldtypeisinstructions,italicisbackgroundinfo)

1. SignouthowevermanycarboysyouneedfromtheSBroomsignoutsheet.Theyshouldbeclean,butyou’llhavetoatleastsanitizethemwithioduphor.Itworksbesttofillthemmostofthewaywithwater,thenaddthechemical,thenfilltofull(chemicalswillfoamsoaddingchemicalfirstthenwaterwillbubbletoomuchtogetanaccuratelevel).

2. FillyourHotLiquorTank(HLT)witheitherhotwaterfromthelargeredhosecomingoffofthebrewery’sHLT(vesselclosesttotheblackdoorsinBay4)oracolddropdownhose.Someattachmentscanbeaddedtotheredhosetomakeuseeasier(askAmandaaboutthese);usinghotwaterwillcutdownonheatingtime.Ifusingcoldwater,planonwaitingabit.



3. HeatwaterinHLTtoafewdegreesoveryourstrikewatertemperature.Thiswillensuremashtemperaturewon’tdroptoomuchoncethegrainisadded.

a. Tousethegasburner,firstopenthepropanetank(rightytighty,leftyloosey–youwantloosey).

b. c. OpenthegasvalveundertheHLTtostartthepropaneflowing.Withthe

lighter,ignitethegasandthrottlebacktheflametowhatisappropriate.4. Whileyourstrikewaterisheatingup,millyourgrain.Pluginthemillandplacea

cleanbucketunderneaththemillgaptocatchyourgrainonceitpassesthrough.a. Thismillisn’ttheeasiesttoadjust–youwantallofthegraincrushed,butnot

pulverized.Ifitisn’tcrushedenoughinitially,passitthroughthemillasecondtime,orasneeded.

b. Grainmilledtoofine(flour-like)willcreateoatmealandwon’tallowforgoodlautering=stuckbed/mash.

c. Grainnotmilledenoughwillnotallowforenoughandproperconversionofstarchestosugarduringthemashstep,andyouroverallgravitywillbelow.

5. Mashin!a. Fillbottomofmashtunwithwater,enoughtojustcoverthefalsebottom

plates.i. WiththepumpoffandValve2closed,openValve3,4and5.

b. Makewaterandgrainadditionsslowlyuntilallofthegrainisadded,startingwithwater.Donotaddgraintoadrymashtun,thisallowsgraintogetbelowthefalsebottomandplugsupthepipesandpump.Thisisbad.

i. Youcanaddwaterfromthebottomorthetop.Followthevalvesequencestatedaboveforbottomfillingor…

ii. Topfilling–CloseValve2and4.iii. OpenValve3and5,adjustingValve5toadjustflowrate.

c. Stirgristslowlytocreateahomogenousmash,removinglumpsandbubbles.Vigorousstirringcanfurthercrushgrainincreasingchancesofastuckmash,andleachtanninsintothewort.

d. Avoidaddingtoomuchwaterandtoomuchgrainatonce.



e. Onceallgrainisin,addenoughwatertocoverthegrainbedbyabout1inch.Turnoffpumpandclosevalves3and5.Positionthetubingatthetopofthemashtuntolayontopofthegrainbedattheoutermost,insideedgeofthevessel.Makesureitissubmergedinthe1inchofwater.

6. Youarenowmashed-inandreadytocirculate.SABCOcallsthis“RIMSrecirculation”,brewersherecallit“vorlaufing”orjustplaincirculating.Thiswillhelpcreateahomogonousmashandavoidtemperaturehotspotsinyourmash.

a. LiquidflowsfromunderthefalsebottomplatesthroughValve2andValve4tothepump.UseValve5toadjustflowrateasitreturnstothemashtunthroughthetubingatthetop.

i. OpenValve4ii. CloseValve2…

b. TurnonthepumpandadjustflowratewithValve5sothatitisabouthalfwayopen.Atfirsttheliquidwillbeclearthenwillturndark,thisisnormal.

c. Maintaintheapproximate1inchofwateronthetopofthegrainbedbyadjustingValve5.

d. TurnonthemashburnerthesamewayyoulittheHLTburnerearlier.NOTE:neverusethemashburnerwhenthepumpisnotcirculatingliquidtoavoidcaramelizationandheatlayering.

e. Besurethetubingisnotpointingdownintothegrainbed,andislayingflatonthetop;thiswillpromotetheflowofliquidthroughthegrain,ratherthanaroundit.

f. Donotincreasethedepthofthewateratopthegrainbed–thismeanstoomuchwaterisbeingpumpedfromthebottomofthemashtuntothetopandwillcompactthegrainbedandleadtoastuckmash.

g. Duringthismashrecirculationtime,useamoderatetolowflametoachieveabouta5degreeperminuterampoftemperature.

7. Followyourmashprofile,rampinguptemperaturetoachieveyourtargettempbyadjustingthemashburnerflame,andrestingbyturningyourburnerdownverylow,oroff.

a. Testthatyoursaccharificationrestiscompletebyusingtheiodinetest.b. Takeasmallsampleofwortandaddafewdropsofiodine.Ifthesample

remainsblack,moretimeisneededtoconvertthestarchestosugar.Ifthesampleisclear,yourconversioniscompleteandyoucanproceedtostep8.

8. Duringyourmashtime,re-filltheHLTforyourspargewater.Heatthiswatertothedesiredspargetemperature.

9. Rampuptomashofftemperature(172˚F)toendenzymaticactivity.



10. Nowyou’rereadytostartrunningoffintothekettle.TheSABCOsystemissetuptoworkbestwitha“fly-sparge”method(describedbelow),butbatchspargingisoktoo.

a. OpenValve3(suppliesspargewaterfromHLTtopump).b. CloseValve4(shutsrecirculationloopoutofthemashvessel).c. OpenandadjustValve2toadjustyourrun-offflowrateintothekettle.d. Turnthepumpon.e. KeepValve5openandadjusttosupplyspargewatertothemashtun.f. AdjustValve2andValve5tomatchflowrates(ideallyslowflowrates)to

maintainthe1inchofwaterabovethegrainbed.g. Turnonthekettleburneroncethereissomevolumeinthevessel.h. Takegravitysamplesthroughoutrunofftokeeptrackofhowmuchsugaryour

wortcontains.Thiswillhelpyoudecidetocuttherunoffvolumesoonerorlaterifthereistoomuchornotenoughsugarinthewort.Itwillalsohelplateronduringboildecideifyoushouldboillongertofurtherconcentratethewortifit’stoodilute.

i. OncethereisenoughvolumeinthekettlePLUSthevolumeleftinthemashtuntoreachthepre-boilvolume,stopthepumpandcloseValve3tostopsparging.

j. Allowtheremainingvolumetorun-offintothekettle,allthewhileadjustingthekettleburnertoreachboilandoccasionallystirringthewortinthekettle.

k. Oncerunoffiscomplete,closeValve2andshutoffthemashburner.11. NowyourkettleisisolatedfromthemashtunandHLTandyouwanttobringthewort

inthekettletoaboil.Adjustthekettleburnerwhileheatinguptoachieveboil.a. Takeasamplefromthekettleforapre-boilgravitycheck.

12. Justbeforeboil,addabout0.5ozofyourinitialbitteringhops.Thiswillrelievethesurfacetensionofthewortandshouldhelppreventboilover.Thisismostusefulifbrewinga10gallonbatch;5gallonsbatchesdonotreachthetopofthekettle,anddonotneedthisstep.

13. Oncethekettlehasreachedboil,startyourboilclock(eitherinthesystem,orbyyourwatch,phone,sundial…).Ifyouhaveanymorebitteringhopstoaddatthestartofboil,addthemnow.

a. Takeagravitysampleonceboilhasbeenreached(fromValve1).14. Addtherestofyourhopsaccordingtoyourhoppingregime,inadditiontoanyother

ingredientsyou’reusingduringboil.Addingingredientsduringtheboilisusefulbecausetheybecomesterilesoextraefforttosterilizethemisunnecessary.Itisgoodtoplaywithingredientadditiontimes;thingsaddedearlyinboilareusuallymoreforflavorandthingsaddedtowardstheendlendmorearomatotheresultingbrew.



15. Whileyou’reboilingisagoodtimetomakesureyourcarboysareready.Ifyouhavenotdonesoyet,sanitizethem,allowatleast5minutesofcontacttime,andemptythemwhenreadytofillwithwort.

16. Fillabucketwithnewsanitizersolution.Placethewortchillerpartsinthebuckettosanitizetheparts,inadditiontotheairlocksforthecarboys.

17. Timetosetupyourwortchiller;Figure1illustratesthepartsneededtodoso.AttachthehosetothekettleoutletValve1andtotheinlettotheknockoutpump.Fromthepumpoutletattachahosetotheinlettothewortchiller.Attachyourrackingcanehosetothewortchilleroutlet.Donotputtheendinthecarboyyet;leaveitinthesanitizerbucket.

Figure1.Knockoutsetupincludinghoses,knockout(transferpump)andwortchiller

18. Attacha1”greyhosefromeitherthewaterdropdowninBay4orfromthebottomof

thefilteredwatertankalsoinBay4(seeFigures2and3forbothwatersources).Ifusingthewaterdropdown,makesurethe1”hoseislongenough.Attachthiswatersourcetothewortchillersothatitrunsoppositetheflowofknockout.Attachadrainhoseontheotherendofthewatersourceonthewortchiller.

Connecttocoldwatersource

WortChillercoldwater

inlet

WortChillerwortoutlet

Hosetofermentation

vessel

WortChillerwortinlet

WortChillercoldwateroutlet

KnockOut(transfer)pump

Drainvalve(usetoprimeonceliquidisrunningthroughit)

WortChiller(heat

exchanger)

TheHotLiquorTank(HLT)isinBay4closesttotheBrewhouse1blackbaydoors.Thereisusuallyaredhose

(2”)attachedtoapipecomingoffofthetank.Byattachingasmallerhoseorfillingupbucketsfromthishose,youcanusethehotwaterfromthe



Figure2.HotliquortankinBay4andsetuptousetousethehotwater



Figure3.ColdwatersourcesinBay4,theoppositeendoftheHLT

19. Onceyourboiltimeisup,it’stimetoknockoutintoyourcarboy(s)!a. Makesureyourcarboy(s)areready,asaretheairlocks/lidsforthem.b. Isyouryeastready?Isitfluidenoughtoeasilypitchintothewort?c. Takeapost-boil/knockoutgravitysample.

20. Withtherackingcaneoutofthesanitizerbucketandpointingtothefloor,openValve1onthekettletostarttheknockoutflowwithgravity.Youcanturnontheknockoutpumphere,butmakesureyoudosoAFTERValve1isopen.Onceyouseewortcomingoutoftherackingcane,putitinthecarboy.

ColdwatersourcesinBay4includethefilteredwatertank(totherightoftheHLT)andawaterdropdownconnectiononthewalltheoppositesideofBay4.1”greyhosescanbefoundinthebrewhousesorinthecellars–askabrewerforhelpifyou

need.

Filteredcoldwatertank,outletat

bottom(2”fitting,willneedareducerparttofittoa1”

hose)

Walldropdownwaterconnection(1”

fitting)



21. You’renowknockingyourwortout!Onceyourcarboy(s)arefull,shakeupthatyeastandthrowitin!Makesuretospraythetopofthecarboyandyourglovedhandswithisopropylalcohol,justtokeepgermsaway.

22. Oncetheyeastispitched,placethesanitizedairlock(s)onthetop(generouslysprayingthecarboyandairlockwithisopropylalcohol),andaeratebyshakingthecarboy(s)aroundasbestasyoucan.

23. Updateyourbrewsheetinyourteam’sfolderintheSBfolderontheMDrivewiththeactualvaluesfromyourbrew.

24. That’sit,yourwortisabouttobecomebeer!Patyourselvesonthebacks,nowit’stimetocleanJ

CIP:

1. DisconnectandremovetheMashandKettlevessels.Dumpspentgraininabucketandtakeouttothegarbagedumpster.Takeoutthefalsebottom(s)andothersmallparts;cleantheseseparately.Hosingoutthevesselsshouldbeenough,howeverifthereisanythingstuckon,orstained,theSBroomhaspropercleaningsuppliesforstainlesssteel.DONOTUSESTEELWOOLorCHLORINEBASEDPRODUCTS(bleach).

2. UsetheHLTtocreatea10gallonbatchofcleaningsolution(causticchemicaltobeprovided/inSBroom)with10gallonswaterand________mLcaustic(AvoidII).Thissolutioncanbepreheatedasitwillaidinthecleaningprocess.

3. PuttheMashandKettlevesselsbackinplaceandre-hookup.4. MovethesolutiontotheMashvesselfromtheHLT.5. RecirculateittoandfromtheMashvesselforatleast15minutes.6. MovethesolutionovertotheKettle;letitsoakforabout5to10minutes.7. Whilesoaking,makesureyourknockoutlinesarestillsetup(resetthemiftheywere

takendown);makeonedifference,flipthewortchilleraroundtointotheoutletandouttheinlet.AftersoakingtheKettle,pumpthesolutionthroughtheknockoutpumpandthewortchillertothefloor.Thewortchillerwillbehottothetouchhere–usegloveswhenhandlingit!

8. Repeatsteps2–7withcoldrinsewaterandmakesuresystemisrinsedthoroughly.9. Afterallissaidanddone,openValve6whichisthedrainvalvetothewholesystem.

DOTHISAFTEREVERYBREWSESSIONasitwillevacuateallliquidfromthesystemandpreventfuturedamagefromcoldortothepump.

10. Hose/wipedowntheframe/outsideofthesystem,particularlyifyouhadaboiloverorareamessybrewteam.

11. Breakdownallclampsandgasketsandplacetheminthemetalmeshbasket.Ifthelargeplasticcut-offtoteinBay4isfullofliquid,hangthebasketintheliquid.Ifitis



not,pleaseemailAmandaandleavethemeshbasketunderneaththeSABCOafteryou’redone.

12. WheeltheSABCObackagainstthewallinBay4,andcleanupallotherparts,andyou’redone!

PleaseemailAmandaonceyouhavefinishedyourSmallBatchBrew.Ifyouhavequestions,orifsomethingdidn’tworkproperly,couldn’tfindsomething,brokesomething…ifnoneofthosethings,justtosaythatyou’vefinished.ThengoaheadandreadSOP#SB03tocareforyourbeer,and#SB04forPost-BrewDayStuff.

Thanks,andhopeyouhadagoodbrewday!

GLOSSARY

• Strikewater–thewaterinitiallymixedwithmaltedgrainstoformthemash• Grist–thegrainsusedtocreatewort,canuseawidevarietyofingredients• Mashingin–combiningthestrikewaterandgristtocreatethemashataspecific

temperature• Mash-OffTemperature–thetemperatureatwhichenzymaticactivityceasestooccur,

signifyingtimeforrunoff• Wort–sweet,sugaryliquidformedfromthestarchesturnedintosugarsfromgrains,

combinedwithyeasttocreatebeerthroughfermentation• Lautering–separatingthefermentablewortfromthemashgrainbycreatingafilterbed

outofthegrainontopofafalsebottom;volumecollectedfromlauteringiscalledrunoffvolumeandiscollectedinthekettle

• Vorlauf–Germanformashrecirculation(literally“leader”),theprocessofpullingwortfromthebaseofthemashvessel(orlautertun)andrecirculatingitbackontopofthegrainbed

• Sparging/Spargewater–hotwater(specifictemperature)pumpedatopthelauteringgrainbedtopushwortinthegrainbedout,aswellasremainingsugarsinthegrain

• BatchSparging–pumpingaspecificamountofliquidatopthegrainbedandstopping,allowingforacertainrunoffvolumetodrainoffthebed,untilpumpingmorespargewateratopthegrainbed



• StuckMash–whenwortcannoteffectivelyrunoffofthegrainbedduetoeithertoofinelymilledgrain(oatmealbed)ortoomuchpressureacrossthegrainbed(toomuchliquidontopandnotenoughunderneathfalsebottom)

• Gravity–theamountofsugarcontainedinwort,measuredindegreesPlato(⁰P)aswholenumbers,orspecificgravity(ratioofdensityofworttowater,sonounits)

• Pre-boilVolume–volumeinkettlerightafterrunoffiscomplete,beforeboil• KnockOut–termtodescribetransferringwortfromthekettleintoafermentation

vessel• Fermentation–thechemicalbreakdownofsugarsbyyeasttoproduceethylalcoholand

carbondioxide(CO2)

DOCUMENTATION:

SAFETY:

REFERENCE:

OwnerSignature:KristenEwer Date:1/2/15

TechnicalReview: Date:

BrewsheetinSBfolder–don’tforgettosaveyourcopyinyourteam’sfolderwithupdatednumbers!

PPE–eyeglasses,steel-toedboots,chemicalgloves



SafetyReviewSignature: Date:

ReviewedBySignature: Date:

RevisionHistoryPage

Rev Originator Date DescriptionofRevision1 KristenEwer 1/16/15 Additionofpicturesandglossary2 3 4 5 6 7 8 9 10 11 12 13 14

Approval:

Quality: Date:

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