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GCP (CAN): Section 5 (CAN): The canning line

Institute of Brewing and Distilling

General Certificate in Beer Packaging
(GCP)
Section 5 CAN
Specialist Section – The Canning Line.
5. CAN: A General Overview of Packaging Plant

A Packaging Line is designed to fill packages with beer and to present those
packages to the warehouse or customer suitably assembled in the most
efficient way while preserving the quality of the beer.

The design of the line will depend on the type of package and how it is
assembled, on the required rate or capacity of the line and on the type of beer
to be packaged.

The packaging line described below refers to:-

A canning line where new cans are presented to the line on pallets and the
output is packed in trays and assembled on pallets.

5.1CAN Principal Plant Items

A flow diagram of an idealised Canning line is presented below:

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (CAN): Section 5 (CAN): The canning line

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (CAN): Section 5 (CAN): The canning line

Principal Plant Items

De-palletiser.

Purpose Features Notes

To remove new cans Mechanical operation using Empty cans are very fragile.
from pallets and to pneumatic/hydraulic rams Numerous moving parts and heavy
present them to a and electric motors. loading means that this machine needs
conveyor for Sensing of positions by maintenance and attention.
transport the line. microswitches and light Work on the machine is dangerous and
To remove the layer beams safety interlocks/safe systems of work are
pads. required.

Can Rinser.

Purpose Features Notes

To remove and particles An ‘S’ shaped belt or a The incoming cans have been received
and dust from inside the twist in the conveyor from the manufacturer but may have
new cans. where the cans are been stored in a dusty warehouse,
inverted and subjected to uncovered.
a jet of clean air followed Rinse water from the jetter should be
by a jet of clean water. checked for debris.

Empty Can Inspection.

Purpose Features Notes

To check that the empty Inspection is either Empty can inspection is not in
cans from the rinser “manually” by eye or widespread use.
meet the requirements electronically.
of:- Electronic can inspectors
• Clean inside & out. scan into the can
• Contain no foreign vertically and reject cans
objects that give an “abnormal
• Are undamaged picture”.

Can filler.

Purpose Features Notes

To transfer beer into the can Filling machines consist of a A detailed
achieving the following parameters:- rotating drum which houses a description of how
• Filling to the specified volume of number of filling heads. The cans the can filler works
beer. are filled as they travel around the is given below.
• Protecting the quality of the beer by drum.
avoiding air pickup and avoiding There are several stations on the
fobbing. filler that are designed to ensure
• Filling at the specified rate. that the cans are filled meeting the
specified parameters.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (CAN): Section 5 (CAN): The canning line

Seamer.

Purpose Features Notes

To seal the can so that:- The seamer consists of a The seamer is
• Beer cannot leak out. magazine that presents the can positioned close to the
• Air cannot get in. Inert gas (carbon ends to the head and a head filler so that air does
dioxide or nitrogen) is used as that seams the end onto the not enter the space
“under-cover” gas (injected under top of the can by folding the above the beer.
the can end) to eliminate the risk of edge of the can end twice
oxygen pickup during seaming. around the edge of the can
• The can is tamper proof. body and closing it tight.
• The can is opened easily when
required for consumption.

Pasteurizer.

Purpose Features Notes

To produce a microbiologically stable For details of pasteurization
beer. techniques see Section 3.

Full can inspection.

Purpose Features Notes

To check that the Inspection is The need for the canner to demonstrate due
full cans from the electronically. diligence in meeting the requirements of both the
filler/seamer meet Electronic can national Taxation (Excise)* authority or Trading
the requirements inspectors throw a Standards* means that inspection is essential.
of:- beam of radiation Often a coarse inspection will take place after filling
• Filled with the through the can at the and a more accurate one after pasteurization.
right volume of beer level. Inspection is backed up with accurate volume
beer. Other methods are by measurement for individual packages. In the case of
• Are bouncing sound off cans this means emptying the contents into a
undamaged. the top of the can to measuring cylinder.
sense its pressure or Records of inspection are kept for the relevant
by measuring authorities.
distortion in the can Details of correct filling procedures are given in the
base. appropriate codes of practice.
Incorrectly filled cans
are rejected.

* Or other national legislative and regulatory bodies.

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GCP (CAN): Section 5 (CAN): The canning line

Hi-cone.

Purpose Features Notes

To clip cans Mechanical operation where a Numerous moving parts means that this
together (in fours roll of hi-cone plastic is fed machine needs maintenance and
or sixes) for ease over the top of two rows of attention.
of customer cans. Forks open up the holes Work on the machine is dangerous and
handling and to and clip these over the cans. safety interlocks/safe systems of work are
present them to a required.
conveyor.

Multipacker.

Purpose Features Notes

A ‘multipack’ is a single Mechanical operation Numerous moving parts means that this
pack containing a group using pneumatic or machine needs maintenance and attention.
of cans that the mechanical grips for The machine is set up for one size of can
customer buys as a unit forming the multi- and muliti-pack at a time..
packs around the Work on the machine is dangerous and
cans. safety interlocks/safe systems of work are
required.

Carton/ Tray packer.

Purpose Features Notes

To put full cans into Mechanical operation Numerous moving parts means that this
cartons or trays (plus using pneumatic or machine needs maintenance and attention.
shrink-wrap), either mechanical grips for The machine is set up for one size of can
loose (Loose pack) or lifting the cans onto and tray.
as hi-cone clusters, or to the trays or cartons or Work on the machine is dangerous and
arrange multi-packs for forming the safety interlocks/safe systems of work are
shrink-wrapping, and to trays/cartons around required.
present all pack formats the cans.
them to a conveyor. Mechanism for folding
the trays/ cartons.
Mechanism for shrink-
wrapping.

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GCP (CAN): Section 5 (CAN): The canning line

Shrink film.

Purpose Features Notes

To cover/surround packs in Mechanical operation Numerous moving parts means
plastic film to give added where a film is draped over that this machine needs
protection and to present the pack which is then maintenance and attention.
them to a conveyor for passed through a heated Work on the machine is dangerous
transport to the palletiser. tunnel where the film and safety interlocks/safe systems
shrinks tight over the pack. of work are required.

Palletiser.

Purpose Features Notes

To stack full packs Mechanical operation using Numerous moving parts and heavy
onto pallets so that pneumatic/hydraulic rams loading means that this machine needs
they are stable and and electric motors. maintenance and attention.
to present them to a Sensing of positions by Work on the machine is dangerous and
conveyor for microswitches and light safety interlocks/safe systems of work are
transport the beams. required.
warehouse. Pallets may be stretch
wrapped for extra stability.

Conveyors.

Purpose Features Notes

To transport cans along Conveyors consist of Metal conveyors need lubrication to reduce
the line. a chain of slats driven friction although cardboard must be kept
The simplest conveyors by an electric motor. dry.
run along straight lines, The slats may be Conveyor speed can be automatically
conveyors can be made of metal controlled to meet the requirements of the
designed to run around (stainless steel) or of a line. For example during a stoppage, the
shallow corners. plastic material. conveyor system can slow down or stop.
Conveying systems are designed with
automated speed control and line sensing
to provide dynamic accumulation between
all the principal line machines
Conveyors are designed to prevent cans
from falling over.

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GCP (CAN): Section 5 (CAN): The canning line

Pallet inspection.

Purpose Features Notes

To check that the pallets from the de- Inspection is Pallets receive hard wear and
palletiser meet the requirements of :- usually ‘manually’ are often damaged.
• Fit for purpose. by eye. Stacking on damaged pallets is
• Are undamaged. hazardous.

Safety.

There are some hazards associated with canning, these are itemised below
along with the normal procedures used to reduce or eliminate them:-

Hazard Safety procedure

Noise. • Plant designed to reduce noise.
• Building design to adsorb noise.
• Use of ear protectors.
Hazardous gases. • Staff awareness of hazards.
Slips trips and falls. • Use of non slip materials for floors and steps etc.
• Regular cleaning of floors.
• Limited use of hoses.
Machinery accidents. • Permit to work procedures for maintenance.
• Guarding of machinery.

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GCP (CAN): Section 5 (CAN): The canning line

In can nitrogen systems.

Beer foam is enhanced and its stability improved when nitrogen gas forms the
bubbles instead of carbon dioxide (see module 6.3). Canned beer is a popular
product in which to use nitrogen, an added benefit being that the can’s
internal pressure, necessary for its strength, can be achieved with lower levels
of carbon dioxide.
The procedure is in two stages:-
• An ‘insert’ (widget) is put into the can before filling that will encourage the
nitrogen gas to come out of solution by disturbing the beer when the can is
opened.
• The beer is dosed with a small volume of nitrogen immediately before the
can is seamed.

When the can is opened, nitrogen is released from the insert and the beer.
This disturbance encourages more nitrogen to come out of solution and form
a creamy head.

There are many types of insert most with a patent, some are designed to
rupture when the can is opened releasing a stream of gas into the beer
causing the necessary disturbance.

For ‘smooth’ beers, a drop of liquid nitrogen is injected into the can just before
the seamer.

Problems associated with ‘in can’ systems can be summarised as:-

• Removal of air from the can which contains an insert before filling.
• Putting the insert into the empty can. This slows down the operation of the
line.
• High pressures are generated in the can, especially during pasteurization.
• Insert performance may be variable.
• The presence of nitrogen softens the flavour of the beer.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (CAN): Section 5 (CAN): The canning line

5.2 CAN: Can Filling Systems

Filling Principles for Beer into Cans

There are a number of types of filler on the market. However, one principle
always applies, and that is beer (like other carbonated beverages) must be
filled under pressure in order to keep the gas (carbon dioxide and sometimes
nitrogen) in solution. Fillers employing this principle are called barometric or
more commonly, counter-pressure fillers.
For beer, filling is more difficult than for other carbonated beverages because
of two unique qualities:
1. Head retention
2. The damaging effect of oxygen

For beer filling it is necessary to remove oxygen from the container before
filling. This is done by pre-evacuating a glass bottle or CO2 flushing a can (or
PET bottle) before filling.

Flushing with CO2, as is the case for cans, will generally give a result above
90% CO2 purity, but it will be lower than that achieved with the pre-evacuation
of glass bottles.

Fillers can be mechanical or electro-pneumatic.

In the mechanical versions, the filling cycle is operated by trips and cams
which are located at set points around the circumference of the filler. The trips
turn the levers on the filling heads, and the cams operate the vacuum and
snift valves. So, in order for the filling cycle to complete, the filler must
continuously rotate. The fill level is controlled by the length of vent tube (short
tube) which returns the gas to the filler bowl. When the beer covers the end of
the tube it prevents the return of gas and therefore stops the filling operation.

With the electro-pneumatic version, the filling cycle is programmed for each
filling head. The filling cycle does not, therefore, depend on the rotation of the
filler for the cycle to operate. This is an advantage when the filler stops with
containers on it, as the filling cycle will continue to beer shut off.
On the mechanical filler, the beer valve can be open and one is dependent on
a perfect seal between the valve and container to prevent over-fill. The fill
level is sensed by a probe and this shuts off the supply of beer.

Fillers can also be volumetric. With these fillers the volume beer can be
metered via a magnetic flow (magflo) meter or alternatively each head is fitted
with a cylinder of a given volume. The volume released by the cylinder is
programmed via a float or conductivity probe.
A filler designed for volumetric filling does not need a ring bowl for beer, but
may well be fed from a constant pressure tank as controlled conditions are
required for an accurate and smooth operation.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (CAN): Section 5 (CAN): The canning line

Can Filler Features.

Purpose Features Notes

To transfer beer into the can Filling machines consist of a A detailed
achieving the following parameters:- rotating drum which houses a description of how
• Filling to the specified volume of number of filling heads. The cans the can filler works
beer. are filled as they travel around the is given below.
• Protecting the quality of the beer drum.
by avoiding air pickup and There are several stations on the
avoiding fobbing. filler that are designed to ensure
• Filling at the specified rate. that the cans are filled meeting the
specified parameters.

The Filling Cycle for Counter-pressure Can Fillers

For cans, the filling cycle starts with air being flushed out with CO2 ( vacuum
would crush the cans). The container is then pressurised until the pressure is
equal to the pressure in the filler bowl; on equalisation, the valve will open
allowing the beer to flow down the inner side of the can. As soon as the beer
reaches the tip of the vent valve the return gas passage will be blocked so
allowing an immediate pressure build up in the can which will, in turn, stop the
beer flowing.

Plan view of Can Filler

3. Filling

2. CO2 Charge
4. Full

5. Snift 1. CO2 Flush

Full cans to the Seamer Empty cans in

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GCP (CAN): Section 5 (CAN): The canning line

Cans are fed onto the filler by a crown wheel which picks them up from the
conveyor, separates them and spaces them so that they fit onto the can lifts
which raise them up to seal on the filling head.
Beer is supplied from the Bright Beer Tank. The temperature of the beer for
packaging must be low (less than 3°C) to keep dissolved gasses in solution. It
may be necessary to install a trim chiller in the line.

The canning machine or can filler has a circular beer tank whose level is
automatically controlled by supplying beer at the same rate as filling cans and
venting off to control top pressure.
Beer Supply to the Canning M achine
Vent CO2

Bright C anning M achine

beer Level
tank
C ontrol

Beer Supply P um p

Canning machine operation:-

1. CO2 Flush.
The rinsed cans are full of air as they leave the rinser, the purpose of the CO2
flush stage is to remove as much of that air as possible.

Gas CO 2

Beer

1. CO 2
Flush

Can lift

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GCP (CAN): Section 5 (CAN): The canning line

Inert gas (CO2 ) is allowed to pass from the space above the beer in the filler
reservoir into the can and out to atmosphere. This flushes the air out of the
can.

2. CO2 Charge.

The can is then counter pressured with CO2 , possibly from the gas space
above the beer in the filling machine’s beer reservoir as shown in the diagram
or from a separate source.

The purposes of counter pressurising the bottle before filling are:-

• To prevent the beer from fobbing during filling. A constant top pressure will
keep dissolved gasses (CO2) in solution.

• To provide an inert gas atmosphere in the can and avoid oxygen pickup.

Gas CO 2

Beer

2. CO 2
Charge

Can lift

When the pressure in the can equals the top pressure above the beer, the
beer will fill the can gently by gravity alone.

3. Filling.

Can filling has to achieve the following objectives:-

• The correct volume of beer in the can. This is achieved by either controlling
the level that the can is filled to as shown in the diagram or by filling the can
from a volume controlled filling chamber.
• To protect the quality of the beer by preventing gas release through fobbing
and preventing oxygen pickup. This is achieved by counter pressuring and
by filling as gently as possible so as not to disturb the beer. A gentle fill is
achieved by running the beer down the inside walls of the can as shown in
the diagram.

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GCP (CAN): Section 5 (CAN): The canning line

Gas CO 2

Beer

3. Fill

Can lift

The beer valve opens to let the beer in while the gas in the can is released
into the headspace above the beer in the filling bowl.
In most fillers, the beer valve opens against a spring when the pressure in the
can equals the pressure above the beer.
If a can bursts during filling, the pressure in the beer chamber closes the beer
valve immediately.

4. Full.

The can is full when the beer level reaches the tube.

With this design of filler, tubes need to be changed for different fill heights;
with a volumetric filling system, a tube change is not required.

Gas CO 2

Beer

4. Full

Can lift

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GCP (CAN): Section 5 (CAN): The canning line

5. Snift.

A controlled snift is introduced to release top pressure gently.

Gas CO 2

Beer

5. Snift

Can lift

The gas space above the beer in the can is pressurised and if this pressure is
released too quickly when the can comes off the machine, the beer will fob.

As mentioned above, some canning machines fill the can with a measured
volume of beer. These are called a volumetric filling machines. The filling
principles are the same but a metering chamber is incorporated in the
system:-

CO2 supply
Beer level probe

Metering
chamber

Beer
supply
valve

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GCP (CAN): Section 5 (CAN): The canning line

The full can is now ready for sealing, but as it leaves the filling machine, any
air present in the can mouth must be expelled.
Unlike bottle fillers and crowners, it has not proved possible to close-couple a
filler with a can seamer. For cans therefore the air is expelled in two stages.
Firstly, there is a bubble-breaker which literally bursts the bubbles lying on the
surface of the beer in order to release any air that may be trapped.
Secondly, while seaming is taking place, gas – normally CO2 - is blown under
the lid as seaming takes place. This is known as under-cover gassing.

Also, the conveyor that transports the cans to the seamer may run through a
tunnel filled with inert gas (CO2 or N2) to prevent air pickup. The area above
the beer in an open can is relatively large.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (CAN): Section 5 (CAN): The canning line

5.3 CAN: Can Seaming

Seamer.

Purpose Features Notes

To seal the can so that:- The seamer consists of a The seamer is
• Beer cannot leak out. magazine that presents the can positioned close to the
• Air cannot get in. Inert gas ends to the head and a head filler so that air does
(carbon dioxide or nitrogen) is that seams the end onto the not enter the space
used as “under-cover” gas top of the can by folding the above the beer.
(injected under the can end) to edge of the can end twice
eliminate the risk of oxygen around the edge of the can
pickup during seaming. body and closing it tight.
• The can is tamper proof.
• The can is opened easily when
required for consumption.

The Can Seam

Seam

Can end

Sealing
compound

Can body

The can ends are expensive and the trend is towards fitting a smaller end by
designing the can’s neck to have a narrower diameter

209 206 202

Can seaming takes place in two stages to achieve the double seam as shown
below:

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (CAN): Section 5 (CAN): The canning line

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (CAN): Section 5 (CAN): The canning line

The Double Seam

Four essential seam measurements

• Correct tightness

• Body hook

• Correct body and end hook overlap

• No other distortions

Cut seams and measure every seamer head every shift

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (CAN): Section 5 (CAN): The canning line

Seam Faults

Both these seams are likely to rupture with high can pressure during
pasteurization

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
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GCP (CAN): Section 5 (CAN): The canning line

5.4 Sterile Filling

Summary

Many packaging operations use sterile filling procedures for bottles and cans
to avoid the need for tunnel pasteurization.
Sterile filling is a term used for filling when it is important to ensure that there
is no pick up of infection during filling. This would apply when beer is filled
after being flash pasteurized or sterile filtered.

Several modifications to standard filling procedures will be necessary to

achieve the higher level of sanitised conditions required, but generally a
modern standard filler can be used for this type of filling, especially if they are
easy to clean. Usually a much more rigourous and disciplined cleaning regime
is necessary to ensure good product stability.

In addition, the filler may be placed in a guarded area which is kept clean, so
that the filler is enclosed in a microbe free environment. This could mean a
separate room or a “shroud” over the filler, either of which is fitted with a
sterile air filter and the air is changed frequently and kept at a slight positive
pressure to ensure no ingress of dirty air.

The immediate working area around the filler (either the sterile room or
shroud) should be regarded as a “sterile envelope” and is likely to have
sterilant sprays fitted in order to drench the whole filler with sterilant (such as
chlorine dioxide) after operators or engineers have had to approach the filler
for whatever reason, so that the sterile integrity is not compromised.

Only operators and engineers equipped with appropriate protective clothing

should be permitted to enter the “sterile envelope”.

Sterile Filling – Operating Details

Sterile filling is more achievable today as standard machines are designed to

be hygienic and are much easier to clean.
The main differences in approach on a line without an in-package (or tunnel)
pasteurizer are:

The beer to be packaged must be sterile i.e. completely clear of all beer
spoilage organisms

The filler installation and layout must be hygienic

The environment around the filler must be free of any organisms which
could infect the beer

The bottles and closures need to be sterile

Cleaning and CIP regimes need to be totally disciplined

The training of personnel in hygiene and methods of operation need to be
carried out to ensure total understanding and commitment

Micro back up from the laboratory is essential

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GCP (CAN): Section 5 (CAN): The canning line

Beer sterilization

The beer can be sterilized in two ways:

Sterile filtration

Plate (or Flash) Pasteurization

Each type has its benefits. Sterile filtration will produce beer that has no heat
damage, and can be installed in-line to the filler making the operation much
simpler. However, the process needs to be closely monitored and filters need
to be well maintained. The method chosen today is usually plate
pasteurization as it is easier and cheaper to manage; also there does not
appear to be any detectable heat damage for the discerning beer taster!
For comparison purposes, the capital cost for the installation of a sterile filter
would be about 50% higher and running costs approximately 3 times greater.
With a plate pasteurizer, however, a sterile buffer tank needs to be installed in
order to balance the system. This is because a plate pasteurizer cannot give
an instantaneous change in supply as the filler slows down, speeds up and
stops!
Another advantage is that with a plate pasteurizer bottles and cans can be
packaged at a higher temperature (which can go up to 15oC), depending on
the gas content. This can be important with regard to keeping finished packs
free of condensation.
Also, for bottle labelling, the bottle needs to be condensate free (dry surface).
Beer from a sterile filter will be around 4oC when bottled, so a bottle warmer
may be required to warm up the bottles before the labels are applied.

Filler Installation and Layout

Good design practices must be followed from the exit of the pasteurizer or
sterile filter right up to the filler. This will include:

No CIP dead legs. Points where the solution will not pass when being
circulated

Valves or caps on T’s less than 1.5 pipe diameters away from the junction

CIP flow rates designed to give high levels of turbulence (velocities > 2m/s
ideally 2.5 m/s)

Use of hygienic fittings and valves

Make pipe runs as short as possible

Do not create traps – all pipe work should be able to self-drain

All gas in contact with the beer is sterile – filtering with a 0.25 micron filter
should be sufficient, and as close to the point of use as possible. Simple
cleaning facility (steam) and easy filter replacement must be considered

In the case of the Sterile Buffer Tank all fittings, including temperature and
level probes, need to be flushed along with the internal surface of the vessel.
The sample cock needs to be a membrane type. Ensure that the programmes
for CIP, flushing, beer intake, changeovers and finish have been precisely
specified to ensure no contamination.

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GCP (CAN): Section 5 (CAN): The canning line

The bottle rinser must be blocked with filler to ensure a short, synchronised
transfer from the rinser to the filler. With a can filler this is not possible so extra
care must taken in the transfer of the cans from the rinser to the filler.

Filler Environment

The environment around the filling area must be hygienically clean. There are
two lines of thought on this:

1. Make sure that the packaging hall, and especially the area around the filler,
are easy to clean, and can be seen as visibly clean – light coloured tiled
floors and walls are best. The hall should be fed with filtered air.
2. As an extra precaution the filler is enclosed with a gap at the bottom to
allow proper cleaning of the floor. The enclosure is fed with filtered air and
a positive pressure is maintained inside the area.

The important thing is to not allow the enclosure to give a false sense of
security. The internal area must be kept clean and the air filters properly
maintained. Any breakages and beer must be quickly washed away with sterile
water and the same strict cleaning regime kept in place.

Sterility of Bottles, Cans and Closures

Bottles can either be returnable or non-returnable. Returnable bottles will

have been treated at a high temperature, and so long as they are shiny clean,
they should be infection-free. However, all this good work can be spoilt if the
final rinse water is contaminated. It is normal therefore to treat the water with
a low level of chlorine 2 to 3ppm, to ensure sterility. Many brewers will not
allow chlorine to be used due the danger of chlorophenol (like TCP) being
formed in the beer should it come in contact with the residual chlorine.
As a result chlorine dioxide at 0.25 to 0.5 ppm or PAA (Peracetic Acid) at 150
to 250 ppm is more commonly used.
For new bottles the same applies – the water, as an extra precaution, could
be passed through a 0.45 micron filter (or less), or be UV (Ultra Violet)
treated. It is also possible to use steam rinsers or rinse bottles with sterile air.
Steam would not be suitable for PET bottles. Chemical treatment with
Chlorine Dioxide or PAA is advised as this treatment is residual. (Remains in
contact with the surface).
It is now a common approach to deliver a sterile bottle to the filler. It is also
possible to purchase a sterile filler which actually steam sterilizes the bottle
before filling, as part of the filling cycle. The downside is that the bottle
breakage increases as the bottle is still hot when the cold beer meets the
glass

Crowns or caps can be sprayed with 300ppm PAA (Peracetic Acid ) or be

treated with UV. However, general advice is to keep them dry in a clean
storage area. Dry crowns will not carry infection.

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GCP (CAN): Section 5 (CAN): The canning line

For Cans, the same principles apply for rinsing. However, cans are not
breakable so can be steam sterilized.
A filler can be purchased which sterilizes the can with steam as part of the
filling cycle.
Ends can be UV sterilized before seaming, however if they are kept dry UV
treatment may not be necessary. Sprays, as used with crowns, are not easy
to apply during end transfer.

Cleaning and CIP

There is no correct way – the important thing is that it is effective in preventing

infection and this will be discovered through trials. For sterile filling, there will
be a need for more cleaning time and this will affect the utilization of the line.
With sterile filling, it is good practice to run the containers out of the filler every
two hours, and then hose down the filler externally with water which has been
treated with PAA or chlorine dioxide. This could take 5-10 minutes which is
equivalent to a 4 to 8% loss of utilization. A full CIP, or internal cleaning;
needs to happen at least twice a week when continuous running. It should
also take place after stops, or at beer changes. The CIP will consist of a rinse,
caustic wash, another rinse, and then finally a rinse with PAA or chlorine
dioxide treated water. External foam cleaning needs to take place after CIP.

Training of Personnel

No person should be allowed near the filler without the proper training in
hygiene and operation. It is important that an assessment of each individual is
carried out after training, and that only certified people are allowed to operate
or maintain the plant. A certain amount of classroom training in hygiene and
operation must be given to the operators and engineers first. It is also
important that proper, simple and straight forward work instructions with
diagrams are prepared for the operation, so as there is no misunderstanding
about what needs to be done. The implications of not carrying out instructions
must be clearly understood.

Microbiological Back Up

So as to ensure that a sterile product is not going to be contaminated, it is

important that all points of contact such as mains, valves, pumps and vessels
are absolutely clean and infection free. A good discipline must be in place for
sampling especially as there is a delay of 4 to 7 days before it is known
whether a product sample is free of infection. Sampling regimes must also be
traceable.

A summary of some good practices are:

An adequate sampling room which allows at least two samples from each
batch to be kept for the given shelf life for the product.

An extra one to two samples to be passed through a membrane filter and
incubated anaerobically for 4-7 days and aerobically for 2-4 days.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)
 24
GCP (CAN): Section 5 (CAN): The canning line

Two samples to be taken for forcing tests and kept in warm storage (25-
30oC) for a period of 4-6 weeks.

Continuous samples are collected from the line feed to the filler every 2
hours from a continuous membrane sampler.

Swabs are taken from plant after cleaning for bioluminescence testing to
ensure cleanliness.

Tests carried out on the water supply, water from the rinser, water from the
tanks and filler after cleaning. Also checks on gas supplies used CO2
(perhaps N2) and crowns. Indeed anything that will come into contact with
the beer.

© The Institute of Brewing and Distilling (GCP Revision Notes Version 1 2008)