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The Institute of Brewing & Distilling

REPORT FROM
THE EXAMINERS
2008

General Certificate and Diploma (both Brewing and Distilling)

as well as Master Brewer reports in one handy volume
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Board of Examiners and Examination Centres 2008

The Board of Examiners 2008 The Diploma and Master Brewer Examinations were held in the following world-wide Centres:

D Taylor (Chairman) UK and Ireland Aberlour Hungary Budapest

Alton India Chennai
A Barker Bedford Mumbai
Burton on Trent Jamaica Kingston
G Bathgate
Cork Japan Tokyo
I Bearpark Cornwall Kenya Nairobi
R Bromley Dublin Malaysia Kuala Lumpu
J Brown Dundee Mexico Monterrey
P Buttrick Edinburgh Myanmar Yangon
Glasgow Netherlands Zoeterwoude
I Campbell
Islay New Zealand Auckland
R Cooper Leeds Christchurch
J B Eaton London Dunedin
T Eppard Magor Nigeria Lagos
T Heywood Manchester Papua New Guinea Boroko
Moray Romania Brasov
C Hughes
Northampton Samoa Apia
R Illingworth Northern Island Seychelles Mahe
R McCaig Orkney St Vincent Campden Park
C McCrorie Tadcaster South Africa Cape Town
S MacLeod Wadebridge Durban
Australia Abbotsford Johannesburg
M Partridge
Adelaide Port Elizabeth
D Quain Brisbane Pretoria
J Robertson Hobart Stellenbosch
H Salisbury Melbourne Tanzania Dar Es Salaam
J Shardlow Perth Trinidad Champs Fleurs
Sydney Uganda Kampala
T Shellhammer
Barbados St Michael USA Atlanta
I Smith Botswana Gaborone Colorado
J Stead Cameroon Douala Davis
W Taylor Canada Calgary Elkton
C Theron Creston Forth Worth
Nova Scotia Ithaca
D Thomas
Toronto Kansas
F Ward Vancouver Milwaukee
Czech Republic Prague San Diego
Dominica Roseau Trenton
France Strasbourg Zambia Lusaka
Germany Munich Zimbabwe Harare
Ghana Accra

The statistics Number of candidates who sat each module

Diploma in Brewing, Distilling & Exam Module 2008 2007

Packaging and Master Brewer Diploma in Brewing Module 1 212 233
Examinations. Module 2 166 175
Module 3 170 153
508 candidates sat all or part of the Institute’s
Diploma and Master Brewer Examinations Diploma in Distilling Module 1 9 16
(553 in 2007) at 66 centres around the world. Module 2 14 14
78 candidates sat all or part of the Master Module 3 14 7
Brewer. 11 candidates accumulated passes in
Diploma in Packaging Module 1 14 NA
all modules.
Module 2 NA NA
379 candidates sat all or part of the Diploma
Module 3 5 NA
in Brewing. 104 accumulated passes in all
modules. Master Brewer Module 1 34 35
32 candidates sat all or part of the Diploma in Module 2 24 26
Distilling. 6 accumulated passes in all Module 3 26 22
modules. Module 4 14 15
19 candidates sat part of the new Diploma in Module 5 20 22
Packaging.

The number if candidates who sat each Split between the British Isles and the rest of world
module of the Master Brewer and Diploma
examinations is shown in the table with the UK & Ireland Rest of World
split between candidates in the UK and
Ireland and the rest of the world. Total Dipl.Brew Candidates 124 255
Total Dipl.Distil Candidates 31 1
Total Dipl.Pack Candidates 10 9
Total M.Brew Candidates 37 41

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Report from the

Chairman of the Board of Examiners

for module 2 and 7 for module 3.

A s in previous years, the results for the 2008 examinations
show a continuing increase in candidate numbers
registering for the examinations, with the average performance
This year saw the launch of the new Diploma In Beverage
Packaging with 10 of 14 candidates passing Module 1 and all 5
across all of the IBD exams essentially maintained this year. In candidates entered for Module 3 achieving passes. The
total this year, there were 11 new Master Brewers qualifying, formulation of Module 2 has been completed, so that all 3
with 101 candidates achieving the Diploma in Brewing and 6 the modules are now available for examination in 2009.
Diploma in Distilling. Also 75 candidates obtaining the GCB and Yet again, all examiners for the written papers for M. Brew.
88 the GCP in November 2007, with 119 and 25 passing GCB and Diplomas commented on the need for candidates to
and GCP respectively in May 2008. In addition, 83 candidates concentrate their efforts in answering the precise questions
obtained the General Certificates in Distilling. Finally, 15 asked, by paying particular attention to preparation, organisation
candidates obtained the new Certificate in the Fundamentals of and time management. There does appear to be insufficient
the Brewing and Packaging of Beer, in April 2008 following a preparation in some cases.
training course held at Durham University. Some specific comments are:
I should like to congratulate all candidates who have attained • Candidates often fail to answer the requisite number of
qualification, especially those achieving distinctions and awards. questions or answer their final question very badly. Good time
In particular, I should like to congratulate Donald Oliver (who management is as important in the examination room as it is at
attended the UC Davis extension programme) for being awarded work.
the June 2008 JS Ford prize (Dipl. Brew.) and Tracey Whyte • Too many candidates fail to read the questions carefully
(Diageo Global Supply) for attaining the Diploma in Distilling enough and either miss out some parts or misinterpret the
Award presented by the Worshipful Company of Distillers. In question; for example, answering a question about mash
addition, Louis Richard De Jager (SAB, South Africa) received conversion systems by describing mash separation systems.
the Crisp Malting award (for the best paper in Dipl. Brew.
Module 1), Peter Aldred (University of Ballarat, Australia) was The examiners for Master Brewer comment specifically that
awarded the Brewery Engineers Association award (for the some candidates still do not seem to be fully prepared in terms of
highest result in the Process Technology section of Dipl. Brew. the technical experience that this high level examination
Module 3) and Niall Conway (Irish Distillers, Pernod Ricard) requires. Again, candidates should seek the help of mentors to
attained the Gin and Vodka Association prize (for best paper in gain the necessary exposure to all facets of beer production in
Dipl. Distill. Module 2). line with the M. Brew. syllabus. Mentors should be encouraging
Finally, congratulations are extended to Tran Thi Ngoc Loan their pupils to get as wide a range of practical brewing
(Vietnam Brewery Ltd) and Simon Barnett (Coors UK) for experience as is feasible in their individual situations and to read
obtaining the Worshipful Company of Brewers award for GCB as widely as possible from textbooks, journals as well as
and GCP, respectively, in 2007 and to Cathy Gilbert (Diageo electronic media.
Global Supply) who received the 2007 GCD Scotch Whisky The results for the GCB and GCP exams in November 2007
Association award. showed some improvement over previous exams (GCB 51% pass
As previously, the 2008 General Certificate awards await the of 148 candidates; GCP 64% pass of 138 candidates), but the
results of the November round of examinations. May 2008 exam produced a marked increase for GCB (69% pass
As ever, I would like to draw attention to the individual of 172 candidates), but only 45% pass (of 55 candidates) for
examiners’ reports following. They are also available via the IBD GCP; strangely, the lowest pass rate (33%) was for those GCP
web site, in the Journal (JIB) or by application to the IBD candidates opting for the Returnable Bottle elective.
Examinations Administration team at Clarges Street. Future The May 2008 GCD exam followed the new syllabus offering
candidates are strongly encouraged to regard these reports as the three alternative options of Cereal-, Molasses- and Grape-
essential reading in that they contain descriptions of the ideal based distillation, with all papers now set in MCQ (multiple
content of answers, sound advice on examination technique and choice questions) format, and achieved a pass rate of 72%,
detailed analysis of the year’s papers. comparable to last year.
For the Master Brewer examinations, the number of entrants With regard to IBD examination developments, as stated
continues to increase year on year. In 2008, overall pass rates and above the Diploma In Beverage Packaging (Dipl. Pack.) has been
pass performances were similar to last year, with 62% pass (of 34 established successfully.
candidates, compared to 17 candidates in 2007) for module 1, Also the Certificate in the Fundamentals of Brewing and
63% (of 24 candidates) for module 2, 58% pass (of 26) for Packaging Beer (FBPB) was set again in January 2008 for In-
module 3, 86% (of 14) for module 4 and 65% pass (of 20 Bev candidates, being a qualification aimed at non-technical
candidates) for module 5. personnel or new entrants to the brewing industry, with an
The results for the Diploma in Brewing in 2008 were slightly examination set in MCQ format. In April 2008, this qualification
down on the results for 2007. Of the individual Brewing was made available to candidates attending the IBD
modules, the pass rates for module 1, (63% of the 212 Fundamentals in Brewing course held at Durham University and,
candidates) and for module 2 (58% of 166 candidates) was less with a slightly modified syllabus, is now available to a wider
than last year, but maintained for module 3 (68% of 170 spectrum of interested candidates.
candidates). The development of a comparable qualification in the
The high pass rate for candidates sitting the Diploma in Fundamentals of Distilling is ongoing and the Distilling group
Distilling examinations achieved last year was exceeded this has now completed an expanded syllabus for a new Diploma in
year, with a phenomenal 100% pass for all three modules! Distilling (like the new GCD) to include elective options for
Congratulations to all 16 candidates for module 1, 14 candidates Molasses- and Grape-based distilled products (in addition to

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Cereal distilling); this will be available for examination in June However, as part of the evolutionary process, I give a warm
2009. welcome to the new members who have been ‘press-ganged’ into
In addition, the Master Brewer team is carrying out a full joining the Board of Examiners this year and for the coming
review of the syllabus, the results of which will be published years.
separately in due course. Finally, but by means in the least, many thanks to the Clarges
As previously, all IBD MCQ format examinations will remain Street based team for their continuing hard work and support.
as paper-based for the time being, but we continue to investigate Special thanks to Jessica Baldwin (née Clark) and Andrea
the concept of on-line examinations for the future. Williams for their outstanding contributions in organising and
This report again indicates a busy, but productive, year for the operating the IBD examination system.
IBD Board of Examiners and the Examinations Department. As To end, good luck to all prospective candidates in the pursuit
ever, I must express my gratitude to all the examiners and of IBD qualifications.
moderators for their important contributions, especially those
who have retired or moved on from the Board this year and, to
them, I give special thanks for their trojan efforts in recent years. David G Taylor

The Institute of Brewing & Distilling

Examinations 2008
Question Papers and Examiners’ Reports

DIPLOMA IN BREWING EXAMINATION 2008 further growth, achieve a stable product suitable for storage and
transportation, develop colour and flavour, preserve the enzymes
Module 1 – Materials and Wort
developed in steeping and germination and inhibit or reduce the
The examination was sat by 212 candidates, compared with 184 formation of undesirable compounds such as nitrosamines. In design of a
candidates in 2007 and 234 in candidates in 2006. The pass rate for the kiln one must keep in mind the three phases of kilning (free-drying,
examination this year was 63%. This compares with a pass rate in 2007 forced drying and curing).
of 70% and 2006 of 73%. The first design consideration is firing, direct or indirect and also the
primary source of energy. The second consideration is radial fan flow per
The grade distribution was as follows (2007 in parenthesis): ton of malt per hour during the three phases, also the bed loading in terms
A: 1% (1%) of mechanics and time as well as the amount of barley per m2. Proper
B: 5% (8%) control in kilning depends on incoming temperature above and below the
C: 18% (30%) kiln, temperature of the external air and the re-circulated air, air
D: 38% (30%) humidity, operating times of the turner (and type of turner) operating
E: 21% (19%) times of the fans and the setting of fresh to re-circulated air. The first
F: 12% (11%) stage of kilning is the Free Drying phase. Air on temperature is 50 – 60°C
G: 4% (1%) and the green malt moisture drops from 45% to 12% over a period of 10-
12 hours.
It is pleasing that very few candidates did not answer six questions; time This stage involves removing water from the grain slowly and
management is a very important part of doing well. The very best transferring it to the exhaust air. It is near the end of this stage that the
candidates showed an ability to write quickly, legibly and clearly, using “breakpoint” is reached, when the band of moisture in the malt reaches
diagrams that were accurately labelled to enhance their answers. The the surface. A rapid increase in the exhaust air will be noticed along with
skill of thinking quickly and concisely is not just important for a decrease in humidity. In this slow moisture decrease of the barley the
examinations, it is a skill required for all aspects of life. Furthermore, the enzymes are protected. In the second stage (Forced Drying) the air on is
ability to communicate knowledge to others is essential. If you have a increased to 60°C and the moisture of the grain is reduced slowly to 4-
passion for producing high quality beer, it is essential that you continue 6%. This process takes 3 to 4 hours. In the third stage, Curing, the air on
to learn and communicate your knowledge. It is a help to the examiners if temperature is increased to 80–85°C, and it is at this stage that colour and
you number each question clearly, for example, Q1, Q2 etc, in this way flavour are developed. In the free drying stage low temperatures and high
sections or parts of answers will not get mixed up. It is also important for air volumes can decrease soluble protein formation and consequently
the candidate to clearly mark on the first page of the examination booklet decrease malt colour.
the questions, in order, that they have answered. High temperatures and low air volumes at this stage could result in
“stewing” which increases soluble protein and final malt colour. At
Question 1 curing the time and temperature affects malt quality: high temperatures
Discuss the basic principles of the design and operation of one type of and longer time reduces the precursor for DMS, reduces enzyme titre and
malt kiln. [10] increases malt colour and aroma. Intensive curing will lower wort pH,
Give an account of the changes, which take place in the malt during increase wort viscosity and increase the Kolbach Index.
kilning, and explain the impact of these changes on malt quality. [10]
Question 2
This question was attempted by 154 candidates (73%) with 63% What are the requirements and specifications (with numerical ranges
achieving the pass mark. The majority of students did very well at this for each parameter) for either Lager malt or Pale ale malt ? [12]
question; however those who failed to identify what happens in kilning Identify four parameters that help to define the “Degree of
did not score as highly as those who wrote properly argued answers. It Modification” of malt, discuss their relevance and outline their
would also please the examiner if the candidates answered the questions methods of analysis. [8]
in the manner that they were posed, rather than weaving both questions
together. This question was attempted by 158 candidates (75%), with 64%
The principle of kilning is to remove water from green malt by passing achieving the pass mark. This question was generally well answered,
a large amount of hot air through green malt. Objectives are to stop with good use of diagrams to illustrate the design and operation of the

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different processes. Weaker answers tended to concentrate on trivial The second section was not covered anything like as well as the first
details at the expense of the bigger picture. section; indeed some candidates elected to ignore this section
Lager malt, in contrast to Ale malt, usually is produced using barley completely! Considering the wide, free choice given here, it was very
with higher protein content. Usually it is germinated at lower surprising that several answers only included detailed description of one
temperature and kilned at lower temp. Lager malt usually gives lower adjunct. Further, very few answers provided full details on composition
extract, lower color, but gives significantly higher enzyme levels. In and influence on wort and beer quality. The most popular choices of
addition, it has a fine mild flavor. Lager malt is used as the basis of most adjuncts, were maize and rice grits followed by wheat malt and roast
of the world's beers in conjunction with specialty malts for added flavors. barley.
Pale Ale malt exhibits higher extract levels, higher color and
homogeneity, but records lower enzyme levels. Since it is kilned at Question 4
higher temperatures than Lager malt, Pale Ale malt gives a slightly The following treatment processes may be required for brewery
toastier malt flavor, which is well suited to production of Pale Ales. Pale water supplies:
Ale malt forms the majority of the grist for a typical UK Pale Ale or demineralisation; [5]
Bitter. A well marked answer included the specifications for the barley selective ion removal; [5]
and the final malt type with the proper units of measure. Those activated carbon treatment; [5]
parameters included sizing, homogeneity, extract (fine/coarse), enzymes, sterilization. [5]
colour, protein (total/soluble), KI, Friability, Free amino nitrogen
content, wort viscosity, odour, and wort pH. Additional marks were given For each process, explain briefly
for those that mentioned other specifications such as storability, free from (a) why the treatment could be necessary,
pests, and free from pesticide or heavy metal residues. (b) how the procedure can be carried out,
Degree of Modification measurements include: 1) Friability (c) its relevance to beer quality.
(Originally an IOB method, and it is quantified by using a Friabilimeter).
It indicates the easiness of the malt kernel can be crashed into powder or This question was attempted by only 96 candidates (45%), with just 30%
flour. It is an index of modification, particularly, is related to cell walls achieving the pass mark. There were very few answers worthy of high
and protein break down, as well as dead kernels. It generates % friability, marks. It is a continuing source of puzzlement to the examiners that
% partly germinated grains and % of glassy kernels: 2) Beta-Glucan questions on water quality and treatment are not popular and usually not
content (an EBC method). It indicates the degradation of cell wells of answered well. It clearly indicates that at all levels, not just at Diploma,
barley endosperm: 3) Fine and coarse difference (Term used in EBC most candidates are not well prepared on this topic, which reflects a lack
method) indicates the difference between coarse and fine grain extracts. of knowledge about the main ingredient of all beers!
The more well-modified the more the smaller the difference. A very Several candidates provided only scant information and many answers
rough estimate of modification: 4) Kolbach index. It is the ratio of total did not address all three topics required for all of the four treatment
soluble N in Laboratory wort produced from the mashing malt by EBC processes. The majority of candidates were unable to distinguish
method to the total N of malt. It is calculated as: KI = {% of soluble N /% between demineralization and selective ion removal, with far too many
of total N}×100 It is related to the degree of protein break down in the answers asserting that reverse osmosis is the ideal process for selective
malt kernels. It is a good indicator for low protein barley malt, but it removal of ions! Also, several candidates wrote apparently knowledgably
could mislead the modification of high protein barley malt: 5) Cold water about carbon filtration, but did not describe the sources of carbon
extract: and 6) Acrospire length. available, nor, indeed, how the carbon is activated.
All in all, a very poor and disappointing performance.
Question 3 Reverse osmosis is, of course, a very effective treatment for producing
Discuss the range of solid adjuncts that can be used in a brewery to demineralized water (also removing many organic compounds also). Full
provide fermentable extract. [12] demineralization is also achievable by ion exchange processes, involving
For two different types of cereal adjunct, describe their composition, a combination of strongly acidic (for full cation removal) and strongly
how they can be used in brewing and their effect on wort and beer basic (for anion removal) exchange resins.
quality. [8] The benefits of demineralised water in brewing relate to giving the
brewer total control over the inorganic content, allowing salt additions to
This question, attempted by 157 candidates (74%) with 61% achieving be made to formulate the exact composition of brewing liquor necessary
the pass mark, was generally answered well. Many candidates displayed for the full range of products required. Also many brewers favour the use
a good basic knowledge of the sources of solid adjuncts and their uses, of demineralized water for alcohol/ gravity adjustment of high gravity-
but several candidates also chose to provide information about liquid brewed beers, making the necessary compensatory salt additions in the
adjuncts (which was clearly NOT required)! brewhouse to achieved desired finished beer ionic specifications. In
There is a wide range of solid adjuncts (principally cereals) available addition, demineralized water is very useful for boiler feed water.
for use in brewing as a source of fermentable extract. Several candidates Candidates could have chosen many different examples of selective

• classical examples are the various decarbonation treatments, i.e. the

set about answering the first part of the question in table format, which ion removal procedures:
worked to some extent, but some candidates did not provide sufficient
discussion, merely presenting a list of potential materials. removal of alkalinity (bicarbonate), by various procedures, such as
Many candidates chose to sub-divide the range of adjuncts into smaller heating, addition of lime or inorganic acids, or use of weakly acidic
groups, and this approach tended to be more successful. For example, cation exchange resins to replace calcium ions with hydrogen ions,
several cereals can be malted, such as wheat, oats, rye and sorghum. followed by a de-gassing tower. All decarbonation or de-alkalizing

• alternatively, use of a softening ion exchange system (strongly acidic

Further many cereals in raw (un-malted) form, including barley, have systems are designed to produce good quality brewing liquor.
starch that gelatinises at mashing temperatures and so can be added
directly to the mashing vessel. Indeed, starch gelatinisation temperature is cation resin) to replace calcium and magnesium ions by sodium ions
a major parameter to be considered regarding use of adjuncts. produces “soft” water, ideal for a number of brewery applications as

• nitrate specific weakly basic anion exchange resins are available to

Rice, maize and sorghum have starch that gelatinises at temperatures process water.
significantly higher than sensible mashing temperatures and so require
alternative processing. Some form of pre-treatment is therefore required. reduce nitrate contents in brewing liquor; important because of

• water containing excessive amounts of iron and/or manganese salts can

This can involve the use of a separate cooking vessel in the brewhouse (as concerns relating nitrate, nitrite and nitrosamine formation.
used for rice and maize grits) or the cereals can be pre-cooked separately
by flaking, micronisation or torrification and then be added directly with be treated by aeration techniques (direct injection of air or ozone) or by
malt. incorporation of manganese dioxide into sand filters, all designed to
Some candidates mentioned the use of refined starch from wheat and form and precipitate the insoluble iron and manganese oxides and
maize and also solid refined sugar from cane. However, very few answers hydroxides.
included discussion on the use of coloured malts (“specialty malts”),
derived principally, but not only, from barley, particularly to create Activated carbon filtration is the preferred system for removal of
speciality beers, although there was some mention of roast barley for chlorine residues and most organic contaminants, including halogenated
stouts. compounds. Treatment involves a pressure vessel housing the activated

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carbon on a gravel bed and water flows down through the carbon bed. surrounding the starch material. Hydrolysis by various proteases (endo-
Activated carbon consists of porous particles (1 to 3mm) with a high peptidase,carboxy-peptidases, amino-peptidase, di-peptidases) exposes
surface area to volume ratio. Key factors affecting performance relate to the starch material and also break down the proteins to amino acids that
the type and grade of carbon (such as coconut shell, bituminous coal, are essential for proper fermentation. The starch material can then be
lignite or bone, with a combination of coal and coconut shell being converted to fermentable sugars through the action of alpha and beta
favoured for brewing water), plus pore volume and pore size distribution. amylases as well as dextrinase.
Coconut shell carbon has mainly small pores (less than 2nm), whereas During mashing for a given malt, the brewer can achieve the desired
coal carbon has larger pores (over 5nm). Consequently coconut carbon is wort carbohydrate composition by alternating the following factors to
more effective for removal of smaller molecules. control/influence the enzymes’ activities:
Carbon filters can be cleaned by both forward and reverse flow, with Milling (Physical state, enzymes titre higher when ground fine), mash
hot water used to regenerate the carbon. Plant is usually equipped for temperature, time of mash, pH of mash, mash concentration, thin or
direct steam injection at the base to allow for steam sterilization. thick, (thin favours diastatic action, and thick mash favours proteolytic
The benefit of carbon filtration is that brewing liquor and all other action), the addition of exogenous enzymes and varying the adjunct level
water sources contributing to the finished product (dilution water, and type.
additions make-up, jetting during bottling) can be guaranteed free of
organic contamination and chlorine residues. Further, chlorine removal
ensures that potential flavour taints arising from chlorophenolic Question 6
compounds, either generated in situ during mashing and/or boiling or Describe briefly, with the aid of diagrams, the basic principles and
generated in hot liquor or even steam residues, can be avoided. operation of the various mills available for commercial brewing [12]
There are many sterilisation techniques available for treating water for Discuss the relationships between the milling and wort separation
all uses in a brewery and the examiner was looking for some detail systems and their impact on wort composition and brew house
describing the various chemical processes involved, such as addition of efficiency. [8]
chlorine, chlorine dioxide, bromine (and bromine based biocides), ozone
and silver ions, as well physical methods like ultraviolet irradiation and This question was attempted by 188 candidates (89%) with 63%
micro-filtration. achieving the pass mark. Many of the candidates only described 2, 4 or 6
Chlorination is still the favoured method for sterilizing untreated row mills, forgetting about wet milling and hammer mills. Exceptional
water. Water purchased from a municipal supplier will contain sufficient answers included malt conditioning. Diagrams were a necessity to
residual active chlorine to ensure safe on-site storage for some time prior achieve good final marks.
to use, whereas own water supply will require chlorination at up to 1.0 The purpose of milling is to make the starchy endosperm available for
mg/l to achieve disinfection during distribution within the brewery. conversion in mashing. Milling effects extraction and extraction yield,
Active chlorine is an effective sterilant by virtue of its strong oxidizing contact time/runoff time, clarity/physical stability and flavour stability.
capability and is most usually used as sodium hypochlorite solution. It is For each of the mill types the candidate was expected to detail the mill
very much the method of choice for “raw” water storage because of low type as well as how each worked including all operational features (for
cost, but must be removed by carbon filtration prior to on-site usage. For instance for dry milling, feed rollers, fluting, sieves, screens, rotational
this reason, some brewers favour ozonation as an alternative. screens and grist composition). A description of the mill and the
Water used for dilution of high gravity-brewed beer, as well as matching separation system as well as a discussion on the reasons for the
requiring de-oxygenation, is often sterilised also, especially if added post match (i.e. roller milling and lauter tuns because of the need for husk
beer filtration. The favoured methods are UV irradiation (where UV light material) was required for full marks. For each system the candidate was
at 256nm effects the destruction of cellular DNA and RNA) or sterile expected to detail the brewhouse and extraction efficiencies as well as the
micro-filtration through very fine absolute filters (at 0.45µ or less). merits of each system in regards to beer flavour (lipids) and physical
Chlorine dioxide in solution is increasingly being used for disinfection stability (polyphenols, tannins).
of process water, finding many applications in brewing, such as vessel
and mains sanitising (as a detergent flush) or in packaging operations
(especially sterile filling of glass and PET bottles and cans) for non- Question 7
returnable package rinsing, prior to filling. Chlorine dioxide is a powerful Outline the manufacturing processes for hop pellets and extracts.[10]
oxidizing agent (2.5 times the oxidizing power of chlorine), but is non- Discuss briefly the relative quality and economic merits of using
tainting (because its action does not involve the chlorine atom), is non- processed hop products, rather than whole hops, for adding
corrosive and effective in a wide pH range against a wide variety of beer bitterness and aroma character to beer. [10]
spoilage organisms.
A further use of sterile water is in jetting in sterile filling of bottles, This question was attempted by 165 candidates (78%) with 59%
where this water supply is often UV treated and sterile filtered. achieving the pass mark. The first section was generally well-answered,
with good use of diagrams to illustrate, by flow sheets, the design and
operation of the various processes. However many answers tended to
Question 5 gloss over the second section, apparently failing to appreciate that this
Starting from the Steeping process, describe in outline, how the carried half of the overall marks for the question. Also, several candidates
enzymatic activities of Malting barley contribute to the production failed even to mention hop oil extracts and the use of the many and
of fermentable wort. [12] various sub-fractions that are now commercially available.
Describe briefly the control factors that the brewer can employ to Most candidates provided good outlines of the processes involved in
manipulate these enzymatic reactions to achieve the desired wort the production of type 90, type 45 (concentrated) and pre-isomerised
composition. [8] pellets, with a few noting the manufacture of type 100 (compressed
whole hop) pellets. In addition, the examiner was looking for brief
This question was attempted by 175 candidates (83%) with 59% descriptions of the manufacture of various extracts using liquid and
achieving the pass mark. This question was poorly answered and good supercritical CO2 and ethanol extraction processes, producing both kettle
answers were accompanied with diagrams illustrating barley structure and isomerised extracts, and many candidates achieved good marks here.
related to enzyme and fermentable formation, and also a diagram Somewhat surprisingly, very few candidates described the production
describing the starch structure of the barley kernel. One thing that was of reduced hop products (“rho-“, “tetra-“, “hexa-“iso-α-acids) and yet
noted was the number of candidates that did not read the second part of discussed their benefits in the second section.
the question carefully, where it was asked “what can the brewer do” and Finally, many answers failed to include descriptions of hop oil-
as a result missed 8 points. enriched extracts or fractionated hop oils and essences.
In steeping the barley kernel is hydrated from 14 to 45% moisture In the main, the discussions in the second section relating to the
through the embryo region of the kernel thereby initiating the distribution benefits of using hop products were very limited. Indeed several
of gibberelic acid, a plant growth hormone through the aleurone layer. candidates elected to provide detailed summaries of the isomerisation of
This initiates the synthesis and release of the hydrolytic enzymes which alpha acids (complete with chemical formulae) and, in some cases,
then act upon the starchy endosperm. The breakdown of the cell wall attempted to draw chemical structures of hop oil components.
structures by beta-glucanases and pentosases exposes the protein matrix Unfortunately, no matter how correct these drawings were, since they had

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no relevance to the question asked, they attracted no marks! polymerisation); protein/polypeptide denaturation and precipitation by
The discussion should have been included the facts that increasing coagulation, plus precipitation of phosphates and oxalate (principally as
“purification” means less storage space requirements (due to volume calcium salts) leading to reduction in wort pH; formation of DMS, by
reduction), increased stability, improved utilisation or efficiency of use breakdown of SMM.
and reduced losses, reduction in chemical (e.g. nitrate) and heavy metal Many answers just included lists of some or many of these chemical
residues, ease of use with the opportunity for automated additions, all of changes and failed to provide any details, even in outline, of the actual
which must be off set by increased costs (directly proportional to degree chemical reactions involved. Those answers that did include such details
of processing). attracted higher marks.
Other “quality” factors should also have been included, such as Good answers to option (b) described in some detail the biological
resistance to light striking and foam enhancement from reduced treatments carried out under aerobic and anaerobic conditions. The
compounds, increased bittering potential, varying bittering potential mechanisms of COD removal by aerobic micro organisms involve a two
from higher cis- to trans- ratios (and implications for reduced loss of stage process leading to the formation of carbon dioxide and water, as
bitterness during prolonged storage of packaged beer), measurement follows:
problems, need for special dosing equipment, handling precautions, etc. COD + O2 + NH3 = new cells + CO2 + H2O;
Finally, discussion was also required of the use of fractionated oil Cells + O2 (auto-oxidation)= CO2 +H2O +NH3
components, use for late kettle hop or dry hop character, separation into Aerobic treatment processes include activated sludge or attached growth
multiple fractions and re-blending to make a wide range of bespoke designs and tend to produce more sludge and reduce COD levels less
products. than anaerobic systems. Anaerobic systems are also 2 stage, but also
produce potentially useful biogas (methane) and good answers again
contained the appropriate equations:
Question 8 acidogenic bacteria + COD = CH3COOH + H2 + CO2
Write notes on two of the following; methanogenic bacteria + fatty acids = CH4 + CO2
a) the key chemical reactions that occur during wort boiling; [10] and 8H+ + CO2 = CH4 + H2O
b) the principal features of aerobic and anaerobic digestion systems In anaerobic reactors, micro organisms tend to grow more slowly than
for waste water treatment; [10] in aerobic systems, so that there are longer retention times, with higher
c) the principles of Quality Management Systems. [10] levels of activity, so that COD removal is higher, with less sludge
production.
This question was attempted by 162 candidates (76%) with 61% The better answers also indicated that optimal treatments may be
achieving the pass mark. Most candidates chose options (a) and (b) to designed as a combination of both systems with an anaerobic reactor,
answer, but most responses to section (c) provided good answers. followed by aerobic.
Option (a) required candidates to demonstrate knowledge of the Option (c) of this question, although the least popular, was, in the
chemistry involved in wort boiling, although most included main, adequately answered with some candidates receiving very good
concentration of wort (caused by evaporation of water) and removal of marks for their descriptions of QMS, including the need for fully
other volatiles; these are, of course, physical factors caused by phase documented systems, Total Quality approaches, ISO-schemes, World
changes. class manufacturing systems, involving GMP, HACCP,
The true chemical changes include: wort sterilisation; enzyme COSHH, supplier quality management, Statistical Process control, etc.
inactivation; solubilisation of hop acids, with isomerisation of alpha Marks were awarded for a structured approach as much as for content.
acids and oxidation of beta acids; colour reactions (Maillard reactions
leading to formation of melanoidins, sugar caramelisation, polyphenol Rob McCaig – July 2008

DIPLOMA IN BREWING EXAMINATION 2008 Table 1: Overall Pass/Fail Rates and Grades
Module 2 – Yeast and Beer Passed 97 58.4%
Grade
Overview
A 3 1.8%
In all there were 166 submitted scripts with 97 candidates achieving a
B 9 5.4%
pass grade to give a pass rate of 58.4%. This markedly lower than last
C 28 16.9%
year (70%), hovering between 2006 (63%) and 2005 (53%). However it
D 57 34.3%
is encouraging that like 2007, there were three A grade passes. Otherwise
the overall performance was disappointing with 50% of the candidates
straddling the grades between a pass (D – 34%) and fail (E – 15.7%). Failed 69 41.6%
Both the examiner and moderator felt this cohort set out to do the bare Grade
minimum to pass this Module. There was no sense of reading around the E 26 15.7%
subject or little in the way of personal comment or insight. F 32 19.3%
Analysis of questions that were answered and the corresponding pass G 11 6.6%
rate was illuminating. Question 1 was answered by 50% of the
candidates with only 30.1% passing. Conversely Q5 was answered by Table 2: Performance by Question
95% with a pass rate of 67% which was just bettered by Q8 at 71%.
Question Answered by Passed by Passed %
Further analysis is presented below.
1 83 25 30.1
Examination technique 2 132 68 51.5
So, as the new boy on the block I came into this eyes wide open. 3 84 40 47.6
Moderating last years Diploma 2 was a great introduction but being 4 136 85 62.5
Examiner is a whole new ball game. Put yourself in my shoes. Lots and 5 157 105 66.9
lots of papers, with mostly six answers per pack which adds up to nearly 6 154 80 51.9
a thousand answers to be marked. So be gentle dear candidate. Mindful 7 131 61 46.6
of this and without wishing to be ‘Mr Grumpy’ there are number of 8 94 67 71.3
things candidates can do to get your examiner and – when it really
matters – your moderator on your side. of questions attempted on the front cover of their answer book’. Of all the
We all have our pet favourites. For me top of the list are the 12 possible transgressions this one is guaranteed to win you no favours
candidates of paper 2 who missed ‘instruction no 8’ to insert the number whatsoever with this examiner!

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It’s all about engagement. You/me have a relationship, albeit This question was looking for a rounded answer that captured the
somewhat distant. Me, I’m looking for you to present your knowledge diversity of sulphur compounds and sources together with their impact
and insight in a way that I can reward with ticks and oohs and aahs of on beer flavour and aroma. Regrettably for some candidates the sum
appreciation. What I rather not have is (i) a writing style that requires content of their answer focussed exclusively on DMS/DMSO. Good
skilled forensic analysis to understand, (ii) answers that are not answers discussed H2S and SO2 in terms of source, flavour impact,
continuous and jump illogically around the answer book, (iii) jokes that metabolic pathway and control. The role of SO2 as an antioxidant and
frankly are not funny and invariably are irrelevant and finally (iv) potential antimicrobial was also rewarded as were notes on the
answers that regurgitate parrot fashion revision/training notes without contribution/role of sunstruck character/MBT, Megasphaera, Pectinatus
any insight or personal connection, opinion or engagement whatsoever. and mercaptans.
Moderator Tobin Eppard also has concerns about some candidate’s use
of time. For example there really is no need to write the question down
unless it is absolutely necessary on your part to understand the question – Question 4
just get right on with your response. Similarly writing up the answer on Describe in detail the ‘additions’ that can be made to beer during
the left hand page and then rewriting it ‘neat’ doesn’t feel like a good use conditioning/maturation and to bright beer tank. [10]
of time. Explain why these additions are made. [10]

Finally 14 candidates failed to answer six questions. Only one passed, The key to this question was to cover not only the ‘what’ but the ‘why’.
just with a ‘D’. So the message is clear, respond to six questions however Marks were offered for the usual list* with additional marks for ‘added
briefly. Marks can be picked up from the scantiest response – remember value’ or insight. Marks were often given as half marks for either what
attempting six answers could make the difference between a pass and a or why. Many candidates rightly presented their answers as a table, with
fail. the best fusing ‘what’ and ‘why’ into a single cohesive answer.

*The list included sugar/syrups, hop products, gases, caramel/malt

Question 1 extracts, antixodidants, liquor, heading agents, haze prevention,
Outline the pathways that the yeast cell uses to reduce/oxidise enzymes, finings and yeast.
Nicotinamide Adenine Dinucleotide (NAD) during fermentation. [12]
Discuss how the concentrations of the products of these pathways
can influence beer flavour. [8] Question 5
Consumers are said to ‘drink with their eyes’. What steps can be
Yeast metabolism can prove to be tricky particularly here where the taken to assure the head retention and clarity of a glass of beer. [20]
candidates understanding, rather than ability to recall and present
metabolic pathways, was being tested. Good answers focussed on the Marks here were split 50-50 for foam and clarity. For simplicity, head
reduction and oxidation of NAD and the routes the cell takes to control retention was broken down into raw materials/process, negative factors,
its redox balance during fermentation. The few 'excellent' papers positive factors, glassware and gases. Marks were given per category
recognized that pyruvate’s involvement in yeast growth results in the with further floating marks for appropriate elaboration, insight or
potential accumulation of NADH which is remedied through the understanding (opposed to bland learning and regurgitating the words).
substantial formation of glycerol. Too many papers dumped all the Similarly clarity was fragmented into headlines of microbiology,
revised pathways into the answer. As the question specified process/raw materials, haze, on-trade/premise hygiene and product (not
'fermentation', no marks were gained for regurgitating the complete all are ‘bright’). Again floating marks for ‘builds’. Some crossover was
Krebs cycle, oxidative phosphorylation or the pentose phosphate inevitable but the same point didn’t get twice the marks! What the
pathways. examiner wasn’t looking for (but often got) was mechanisms of
Part b was looking for the candidates knowledge on the flavour/aroma formation (foam/haze) or methods of measurement (often in painful,
contribution of the various NADH dependent pathways. Marks were protracted detail).
awarded for correct identification of metabolites, insight into their
contribution to flavour and/or aroma and typical concentration in beer
and flavour threshold. This question was answered by only 50% of the Question 6
candidates (with a disappointing overall pass rate of 30%) and Write notes on the following topics
regrettably – for many of them - was a great example of answering the a) storage of pitching yeast [10]
question they wanted rather than the question that was posed! b) measurement of pitching yeast concentration. [10]

For storage, pretty straightforward, marks for informed comments on

Question 2 time, temperature, headspace gas, stirring (noting reduced shear), ABV,
Explain how the composition of beer and its processing can minimize hygienic design, slurry v cone to cone or cake, selection of ‘best’ yeast,
the threat of microbiological spoilage. [20] cropping best practice and a floating mark for acid washing/dilution
liquor quality or glycogen maintenance. Similarly measurement was
Although some candidates missed the point, this question was arguably vital stains, capacitance, spun solids etc with additional marks around
pretty straightforward! Firstly the product parameters that contribute to importance. A decent drawing of a storage vessel would grab a mark but
building microbiological robustness. Included here was ABV, iso- α trotting-out stuff about vitality or step by step methodology on how to
acids/reduced hop materials, nutrient depletion, pH, oxygen control, use a haemocytometer failed to garner a mark. Too many candidates
water and microbiological specifics (where appropriate). Consideration missed – or chose to ignore - the key word of ‘pitching’. The plethora of
of ‘process’ factors was somewhat meatier. Basic answers would include laboratory storage methods and their pro’s and con’s whilst interesting
CIP, wort boiling, pasteurisation, (sterile) filtration, sampling plan with and broadly correct in terms of conclusions was also not rewarded.
better responses folding in raw materials, fermenter and yeast
management, water quality, prevention of air ingress, process gas
hygiene, hygienic design, recovered beer management, draught beer Question 7
hygiene and operator training. Explanations ‘why’ these parameters How, why and when are the following parameters measured during
impact on the propensity for microbial spoilage were rewarded where the brewing process.
appropriate. Surprisingly some candidates dealt exclusively with either a) dissolved carbon dioxide [4]
'product' parameters or 'process' parameters and accordingly were b) dissolved oxygen [4]
marked down. c) specific gravity [4]
d) alcohol [4]
e) pH [4]
Question 3
Describe the formation and implication for beer flavour of sulphur This broke down neatly into nominally a mark each for ‘how’, ‘why’ and
compounds. [20] ‘where’ with a floating mark for excellence. In many cases the examiner

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and moderator resorted to half marks where there was insufficient detail fermentation and in beer processing would – depending on clarity
or understanding. The ‘why’ was frequently poorly answered. Similarly (diagrams helped here) and depth – gain a mark or two. Bonus marks
many candidates did not have a good understanding of the “how” – we were awarded for points of detail (sprayball location/performance, total
suggest that future candidates garner a better feeling for laboratory dump v recovery, carbonate conductivity, monitoring/validation).
methods as they are key to control of the process. Of the eight questions, The HACCP question was surprisingly poorly answered. What was
only Q1 performed more poorly than this question despite almost 80% of required was a broad understanding of what HACCP is about and where
the candidate answering it. it sits in the QMS, the six or so steps of hazard analysis, its site wide
organisation and something about the challenges and approaches to
practical implementation. This is again, key to understanding the basis of
Question 8 quality systems and control methodologies that ensure product safety and
Select two of the following topics to answer. system reliability. We wholeheartedly suggest that an understanding of
Outline the formulation, application and typical working HACCP will be a useful investment to maintain the quality of your
concentrations of CIP (cleaning-in-place) detergents and sanitizers products.
in the fermentation and beer processing areas. [10] Staling and control was generally well answered. An overview was
Describe the application and implementation of Hazard Analysis appreciated especially if coupled with the Dalgiesh chart detailing the
and Critical Control Points (HACCP) analysis. [10] timeline of sensory change. Marks were offered for
The staling of beer flavour and its control. [10] descriptions/discussion of staling reactions with the remainder of the
The best performing question with a pass rate of 71.3%. The CIP marks rewarding best practice for minimising flavour instability in
question was reasonably formulaic. Noting the importance of CIP earned process and in package.
a mark. The majority of the marks were awarded for knowledge in
describing acid and alkali detergent make up together with the principles
and diversity of sanitisers. Description of a typical CIP cycle in David Quain – July 2008

DIPLOMA IN BREWING EXAMINATION 2008 and all four dropped only one question. By comparison, 19 of the 55 failed
Module 3 – Packaging and Process Technology candidates did not complete six questions.
As in previous years, candidates performed better on the packaging
questions (Section A) than on the process technology question (Section B)
The overall pass rates, and details of candidates’ performance on which contains calculations. Here are a few hints to prospective
individual questions are shown in the tables below. candidates about answering calculation questions. The Examiner is
looking for a clear demonstration of method in working through the
Table 1: Overall Pass/Fail Rates and Grades calculation. The correct answer at the end of the calculation is welcome
Diploma in Brewing Module 3 - June 2008 but alone does not receive many marks. So doing the calculation on scrap
paper, in your head or on the calculator keypad and just giving an answer,
Number of Candidates: 170 will not get good marks, even if it is correct. So an answer could start with
Passed 115 67.7% writing out the relevant equation – in full, at this stage and then, if
Grade A 13 7.7% relevant, explain why certain terms in the equation can be deleted. For
B 22 12.9% example in a flow question, Bernoulli is an energy balance equation and
C 41 24.1% should be written out in full, with all terms (potential, pressure, kinetic,
D 39 22.9% friction and pump terms) between two points, A and B. Then perhaps
some terms can be eliminated or cancel out, for example PA and PB might
be cancelled if both dispensing and receiving tanks are at atmospheric
Failed 55 32.4%
pressure so PA = PB. Show all workings, since, even if the arithmetic goes
Grade E 28 16.5%
wrong, marks will still be awarded for progressing through the calculation
F 17 10.0%
correctly.
G 10 5.9%
And finally, always answer the question and not what you happen to
know. If the question says, “draw a diagram”, draw a diagram. Don’t write
Table 2: Performance by Question
out a list or an explanation of items if not asked for. The marks are for the
Diploma in Brewing Module 3 - June 2008 diagram and it is a waste of valuable time providing written material that
Question Answered by: Passed by: Passed % will not get marks, no matter how good or accurate the information.
1 133 86 65 And one last thought: if the Exam instructions say – “fill out the
2 81 58 72 numbers of all questions answered, in the order answered, on the front of
3 63 46 73 the first book” – do it! Why should the Examiner have to do it for you?
4 114 99 87
5 104 79 76
Question 1
6 158 109 69
Sketch the flow layout of a flash pasteuriser. Describe features in the
7 63 36 57
design of the pasteuriser and the precautions in its operation and
8 92 51 55
maintenance that need to be taken to guarantee integrity. [8]
9 55 38 69 Explain the terms “pasteurisation” and “pasteurisation unit”, and
10 114 64 56 illustrate, with the use of diagrams, the relationship between time,
temperature and lethal rate. [6]
General Comments: Outline the factors, other than time and temperature, which can
The pass rate at just below 68% was a little lower than last year (70%). affect the survival of organisms. [6]
However, there are unfortunately still a number of candidates who are
sitting the exam clearly with little or no preparation and this cannot be This was the most popular question on the paper, probably because it is a
helpful to a candidate’s morale. Ten candidates scored less than 25% and topic that has appeared many times before and should have been covered
5 less than 15%. Companies must take some responsibility in making in most candidates preparation for the exam. However the pass rate at
sure, through mentoring and training, that their employees are given the 65% was disappointing. Sketches of the flow layout were generally good,
best chance of passing this exam and not to enter candidates until they are but still a fair number that were very messy, with not a single straight line
capable of making a reasonable attempt. and much crossing out and re-drawing. The question was looking for the
Candidates are advised to answer six questions and it is of interest that things in the design, operation and maintenance that could compromise
only four candidates passed the exam by answering less than six questions integrity, so a good approach would be to list them under each heading –

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design, operation and maintenance. In design, the plate material, pressure Due to variation in tare weight, filled keg contents cannot be checked
rating and back pressure control to prevent gas breakout, a boost pump to by full weighing alone - (except possibly with a brand new population of
raise the pasteurised beer above the unpasteurised beer pressure (and also identical kegs). Tare weighing of the kegs can be done on-line or the kegs
above the heating and coolant agent pressures) and accurate temperature can be pre-weighed and bar-coded or fitted with transponders which can
and pressure probes and their use in control, should all be stated. be read at the fulls weigher and used to calculate net weight. Hence
In operation, good CIP and sterilisation at start-up, recirculation or shut- knowing the beer SG, it is possible to calculate the volume filled and
down on low temperature and pressure, avoidance of recirculation of beer calibrate the beer meters. Otherwise, off-line destructive weighing and
and continuous membrane sampling are a few of the measures looked for. emptying of batches of kegs from known filling lines is needed in order to
For maintenance, frequent test procedures for plate integrity and regular calibrate the meters and fulfil legal weights and measures requirements..
calibrations of temperature and pressure sensors are needed. The filling of kegs can be brimful - detecting overflow by conductivity
The second part of the question, after the straightforward definitions of on the fob line - but this can cause high losses and extra duty payment on
pasteurisation and pasteurisation unit was looking for the Del Vecchio the extra beer above nominal. Meters are routinely used but their
thermal death curve of log time versus temperature indicating the lethal calibration is key to achieving consistent contents.
zone for a particular organism. It was encouraging that most candidates Particulate matter in packaged beer – most candidates were able to
were aware of D and Z values and knew what they were and could quote explain the possible causes of particles in beer as either microbiological or
that the typical Z value for brewery organisms was 7°C (actually 12.5°F or non-microbiological. For the former a recheck on cleaning, sterilisation
6.944°C) and pasteurisation procedures would be called for, and also the efficacy of
The final part of this question looked for the factors, other than time bottle washing, and possible contamination of jetting water and rinse
and temperature, that could affect organism survival. Most candidates waters. Non-microbiological haze can have a number of causes – protein-
were aware that alcohol, CO2, low pH, hops and moisture all affected polyphenol chill haze or permanent haze, denatured fob, filter aids,
them adversely, whereas cell density, proteins, saturated fats (lipids) and oxalate, starch, b-glucan (“invisible”) haze and those caused by additives.
sugars are all said to protect organisms. The age and physiological state of Loss of foam potential – Beer has a wealth of foam positive factors, so
the organisms can also affect survival. poor foam is usually the result of foam negative agents coming into
contact with the beer. In packaging, lubricants, used on the filler and
seamer, need to be carefully controlled to avoid contaminating the
Question 2 packaged product. The empty bottle may have had excessive or
Write brief notes, in the context of packaging, on FOUR of the misdirected cold-end treatment (inside the bottle) during manufacture.
following: [5 marks each] Conveyor lubricants can be fat or oil based and care taken to avoid transfer
• hazard and critical control points (HACCP) into the open package. Gross contamination of a bottle washer or keg
• head space air washer can occur from the contaminated contents of the containers
• empty bottle inspection returned from trade – cooking fats, vegetable oil, diesel oil etc.
• predicted and actual shelf life Beer foaming should be avoided since it can lose carbonation and cause
• keg contents checking haze. Low carbonation and/or nitrogenation can cause poorer foam than
• particulate matter in packaged beer required.
• loss of foam potential Can seam evaluation – Most candidates were aware that can seam
• can seam evaluation evaluation was essential to check seam integrity and so eliminate leakage
and ingress of air. Better answers gave an annotated diagram of the seam
This question was selected by less than half the candidates, despite there cross-section after tear-down with the components and key measurements
being a choice of topics – four from eight. of a double seam highlighted, such as seam length, countersink and seam
HACCP – originated by Pilsbury Foods and taken up by NASA for thickness. The calculated parameters from the seam measurements, such
food preparation for astronauts, HACCP is a system for assuring a as actual overlap, tightness rating, body hook butting etc, were mentioned
process. It was the basis for the UK Food Safety Act 1990 which was by the best answers.
adopted by the EU in their Directive of 1993. This question was looking
for explanation of the seven principles of HACCP.
Head space air – The head space air is one component of total in- Question 3
package oxygen (TIPO) and it is important to control headspace air if low Outline the basic principles of operation of a CIP system for a
TIPOs are to be achieved. Bottles can be double evacuated and purged packaging plant and explain how the pipe work and fittings for a
before filling and jetted, vibrated or knocked before crowning so that packaging plant, and its associated tanks, are designed for effective
foam displaces the air in the bottle headspace. Long tube fillers give better CIP [12]
results than short tube but are slower. Cans are too weak to be evacuated How can the microbiological and chemical cleanliness of a packaging
but can be purged to give a lower air content before filling. The wide plant be checked? [8]
surface area of the beer after filling requires blanketing and/or bubble
breaking to remove air and under-cover gassing immediately before the This was one of the least popular questions but well answered by most
can end is applied. Kegs have a low air prior to filling due to being sealed candidates who attempted an answer (73% pass rate).
from the atmosphere and purged with steam and CO2 during the washing The basic principles of a CIP system needed to cover the following key
and pressurising cycles. points: cleaning without dismantling, mechanical and chemical action,
Empty Bottle inspection – essential for both NRB and RB lines for line time and temperature. For packaging, soil levels are usually lower than
performance and customer protection. Can be manual or automatic, but other brewery systems and requirements, such as higher cleaning
the latter is more reliable for modern line speeds. Machines use air frequency and sterility, are different. So a separate facility is
pressure, radio frequency, visible light, lasers, ultrasound and physical commonplace. CIP can include external cleaning of plant (e.g. foam
checks to detect defects. It is important to check the machine/s at least cleaning) as well as internal. Systems can be total loss or total recovery or
once per shift with test bottles containing typical defects. a hybrid with a bit of each.
PSL and ASL – The actual shelf life (ASL) needs to greater than the A typical CIP cycle should have been described, with temperatures,
declared product shelf life, but quick checks (predicted shelf lifes - PSLs) concentrations and times and with some, or all, of the following: pre-rinse
are needed for product release as a means of gauging likely ASL. Before using recovered final rinse, caustic circulation, acid circulation, final rinse.
packaging, beer stability can be assessed by tests such as the Chapon sterilent circulation and possible re-rinse, or hot water/steam sterilise –
Alcohol Chill Test, and others. Once packaged, accelerated ageing tests depending on the circuit described.
by temperature cycling, or forcing by high temperature storage, can be The key features of pipe work and plant design for effective CIP are:
used to estimate shelf life. Retrospective correlation of these PSL tests Pipe work – hygienic design, no crevices, dead-legs, polished and laid
with actual ASL results are needed to affirm which test has the best fit for to falls with no hollows or humps (air pockets). Flow rate on CIP >2m s-1,
your beer. continuous welded pipe where possible with fewest fittings.
Keg Contents checking – There are two issues – contents, possibly Tanks – effective spray device for size/shape of tank (high pressure/low
contaminated, in empty kegs returned from trade, and checking the volume or low pressure/high volume), effective scavenging to avoid
contents of filled kegs on-line. From trade, pressure testing, weighing and pooling, no shadows from coils and fittings, hygienic anti-vac relief
hydrocarbon sniffing are all used to detect problems. (caustic + CO2 filled tank = flat tank!) and cleanable pressure relief valve,

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“new” (clean) door rubbers and new dairy sample point rubbers at every Explain why most heat exchangers for brewery use will be configured
clean. to run counter-current and explain the circumstances when co-
To check the efficacy of CIP, checks could be invasive or non-invasive; current might be the preferred choice. [4]
the former possibly requiring a re-sterilise afterwards. Simple things to be Explain why hydraulic pressure shocks on the plate pack are to be
checked are times, temperatures, flow rates and concentrations of the avoided. [2]
process just completed. It was pleasing that some candidates suggested a A counter-current wort cooler, is operated under the following set of
visual inspection for soil, surface wetting and debris – all too frequently conditions:
forgotten when operators never have to leave the control room. Wort flow rate 5 kg/s
Most candidates were able to outline swabbing techniques and Water flow rate 5.5 kg/s
sampling of final rinse water for testing for chemical and microbiological Wort Inlet 98°C
residues, describing the tests carried out for each. However, far too many Water Inlet 8°C
candidates just suggested “ATP” without defining on what, how, where or Wort Outlet 14°C
when the test was to take place. After CIP, new in-line membrane If the exchanger has a surface area of 100 m2, what is the value of the
sampling or discreet product samples can be taken and checked as overall heat transfer coefficient? [8]
assurance that all is well.
Data
Specific Heat (cp ) of water = 4.2 kJ kg-1K -1
Question 4 Specific heat (cp ) of wort = 4.0 kJ kg-1K -1
Sketch a fully labelled layout of either a keg racking line or a bottling
line, showing all the main items of equipment. [10] The first part of Question 6 was looking for the mechanical design
Describe how this layout facilitates the handling of empty and full features of a plate heat exchanger, so a flow diagram was not the required
containers onto and off the line, accumulation and handling of answer. Plate material and thickness, embossing and small flow gap to
rejected containers and waste materials. [10] give high turbulence and very high U value were the sort of information
items required.
The highest pass rate of 87% for this popular question is evidence that The co-current and counter-current configurations were well explained
most candidates knew what a packaging line looked like and could and most candidates were aware of the reasons for their selection:
reproduce a diagram of the main plant items without too much difficulty. counter-current for energy efficiency and best use of the coolant
For their chosen layout – straight-thro, U-shape, comb or arena – better temperature, co-current for situations where freezing would be a real
candidates described the advantages, or otherwise, of segregating Fork possibility with counter-current.
Lift Trucks (FLTs) from operators and utilisation of the FLTs and Hydraulic shocks are to be avoided due to the potential for blowing out
operators for full and/or empty containers. Also, empty and full stock gaskets and consequent hazard to operators and visitors from hot fluids,
segregation, particularly for cask and keg, may be vital to avoid mix-up. downtime to make repairs and, in extreme situations, irreparable damage
For accumulation, most candidates described the V-graph of plant running to the gasket groove necessitating complete pack replacement. Titanium
speeds and better candidates outlined the benefits of dynamic plates are also susceptible to cracking from flexing leading to leakage or
accumulation compared to accumulation tables and other accumulators. cross contamination.
How the layout lends itself to the easy collection and movement of The calculation of the overall heat transfer coefficient required firstly a
rejected containers, and other waste materials from the line was poorly calculation of the water outlet temperature at 80.7°C, so that the
answered with a lot of candidates saying no more than that they would be DTLMTD between the two fluids – wort and water - could be calculated
amassed somewhere after rejection. There are rejects of empty containers as 10.66°C.
(“foreign”, damaged, wrong size/shape, contaminated), full containers If the average DT of 11.65°C was used instead of the DTLMTD, a
(recheck - “good” rejoin line, “bad” – part-full, washer reject, repair, scrap mark was deducted. Similarly, a mark was deducted if the units for U (W
etc) and each needs a route. Other wastes such a bottle washer pulp, m-2K-1 or kW m-2K-1) were not given.
broken glass, damaged cases etc. also need to be catered for in the design.

Question 7
Question 5 Outline the properties of austenitic stainless steel and name two
What are secondary packaging materials? [4] commonly used austenitic stainless steels and their compositions. [4]
Explain the role and the desired properties of a secondary packaging Explain why they are the preferred material of construction for many
material for ONE of the following primary beer packages:- items of brewery equipment and give one example of where an
• cans alternative grade of stainless steel should be used. [4]
• non-returnable bottles. [10] Explain how weld decay of stainless steel can occur and the changes
Outline the impact of secondary packaging materials on the that can be made to the stainless steel composition to improve its
environment and how their effect can be minimised. [6] resistance. [6]
Describe the process of stress corrosion cracking (SCC) of stainless
Whilst just a few candidates confused primary, secondary and tertiary steel and the factors that compound the potential for SCC attack. [6]
packaging, the majority were able to say that secondary packaging
collates, protects and markets the primary packages for the convenience of One of the three least popular questions, despite requiring little more than
retailer and customer. textbook reading of the topic in order to be able to fully answer the
The second part of the question looked to the candidate to expand on question. The pass rate at only 57% indicates that all too few had done so!
the previous answer by defining, for one secondary package alone, its role Austenitic stainless steels are alloy steels containing chromium and nickel
and its properties that make a good product. Role covers: collate, protect, with high resistance to corrosion, non-magnetic, good weldability,
inform, market and sell and properties: strong, durable, printable, ductility and good strength at both high and low temperatures – features
attractive, visual, lightweight, machineable, cheap, available and that explain their prevalence for brewing equipment.
recyclable. The two main grades in use in brewing are AISI 304 and AISI 316 and
The environmental issues of packaging materials was well answered by their low carbon alternatives 304L and 316L. The Examiner was not
most candidates, and covered the five “R”s in their most beneficial order looking for exact figures for composition, since there are ranges,
to the environment – reduce, reuse, recycle, reclaim and recover, or (although several students excelled in providing this detail), but
similar combinations of “R” words! candidates should be aware of the ball park figures.
Better answers covered individually the main groupings of secondary • AISI 304 – 18 –20% Cr, 9 – 11% Ni, < 0.08% C or < 0.03% for the L
packaging materials - cardboard and paper, plastics and wood. version
• AISI 316 – 16–18% Cr, 10 – 14% Ni, < 0.08% C or < 0.03% for the L
Section B – Process Technology version and 2 –3% Mo.
Although AISI 321 was mentioned, it is not now in common use, being
Question 6 intermediate in properties, and cost, between 304 and 316.
Outline the mechanical design features of a plate heat exchanger. [6] Whilst a few of austenitic steel properties are given above, there are a

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number of other important factors in their selection for brewery use. equation is total head and is a combination of the pressure difference,
They are non-toxic, non-tainting and insoluble in most brewery expressed as head, the static head and the friction head – kinetic heads
applications. They have good corrosion resistance across the pH range of being neglected as not significant on this occasion. A lot of candidates
brewery fluids – 2 – 14. They can be polished for good appearance and show reluctance to use the Bernoulli equation in “pressure” units. That is
give a smooth surface not conducive to micro growth. Maintenance of OK provided all terms from the Bernoulli equation are converted to head.
plant, both internally and externally is low since stainless steel does not By staying in “pressure units” (Pa), the pump power, in watts, is the
require coating or painting and can be cleaned effectively with CIP. On the multiple of pressure (Pa) and volume flow rate (m3 s-1) since also po = Q
negative side, they have low conductivity relative to other steels, but using DP. It is a note for trainers that candidates should be able to manipulate the
thin section material due to its high strength often compensates for this. equation between “pressure” units (N m-2 or Pa), “energy” units (N m kg-1
Also, they are poorly wetted, which has implications when used in heating or J kg-1) and “head” units (m).
and boiling situations. The Reynolds number calculated should have indicated that turbulent
Austenitic steels are not suitable in situations where high temperature, flow existed. Laminar flow would be preferable for transferring beer from
low oxygen and chloride are all present, as might be encountered for BBT to filler but it is not achievable in practice at the flow rates required
example in a hot liquor tank. For this use, ferritic or Duplex steels are and realistic pipe diameters. Given that flow will be turbulent, additional
preferred. agitation should be minimised by the use of long radius bends, few
Weld decay occurs adjacent to the weld, not at the weld itself, when intrusions or devices, such as valves, and adequate top pressure on the
two pieces of s/s are joined. In an area where the temperature reaches 650 filler bowl and low beer temperature to prevent gas breakout.
- 800°C, chromium will migrate and react with the carbon in the steel to The final part using Henry’s Law was quite well answered with a result
form chromium carbide. This depletes the chromium available at the for CO2 content of 5.07 g l-1, remembering that the pressure in the Henry’s
surface to oxidise and form the chromium oxide passive layer, leaving the equation is absolute pressure, and not gauge pressure.
steel vulnerable to corrosion. The problem can be tackled in two ways –
by reducing the carbon content to less than 0.03% (the L versions) so that
there is less carbon to react with chromium, or to add titanium (as in Question 9
316Ti) or niobium to the steel, since they have a greater affinity than Describe, with the use of diagrams, THREE instruments used for
chromium for carbon, leaving the chromium still available to form the measuring flow, each of which is based on a different principle of
passive film. operation. Discuss the advantages and limitations of each type of
Stress corrosion cracking is the most serious of all forms of stainless instrument and give an example where the instrument would be used
steel corrosion, occurring across the granular structure of the steel, for flow measurement in the brewery. [12]
without material loss, and causing very rapid failure for which no repair is Explain the operation of each of the following control systems, with
possible. It initiates from a small area of localised attack where the passive their respective advantages and disadvantages, and give one typical
film has been disrupted. The conditions that are particularly conducive to brewery application of each control system: [8]
stress corrosion are residual stress in the material, temperature in excess • feedback control
of 60°C, free chlorine ions, time and continuous operation of equipment. • feedforward control
• cascade control
• ratio control
Question 8
Beer, at 5°C, is pumped from a bright beer tank (BBT) to the filler The most unpopular question of the whole paper – which was surprising
bowl of bottle filler through a pipe of 100 mm internal diameter at a given that the first part of the answer was textbook material. However the
flowrate to match the maximum filling speed of 1,000 bottles per question did ask for instruments based on three separate principles and

• electromagnetic
minute of 500ml capacity. The BBT and filler bowl have a CO2 top these could be taken from the following:-

• ultrasonic
pressure of 1 bar gauge and 1.5 bar gauge respectively. Calculate the

• vortex shedding
following:

• differential pressure (e.g. venturi, nozzle, orifice plate, pitot tube)

a. Reynolds number for flow in the pipe if the viscosity of beer at 5°C

• positive displacement (e.g. diaphragm, piston, turbine)

is 0.0015 Pa s. State whether the flow is laminar or turbulent and

• variable area (e.g. rotameter, notch weir)

comment on the flow conditions in the context of filling operations. [4]
b. the maximum power input (kW) required by the pump set, of 60%
overall efficiency, when the differential hydrostatic lift between the Diagrams were often poor with items missing – for example an orifice
BBT and the filler bowl is 10m and the flow pressure losses due to the meter without any pressure tappings – and quite often the underlying
pipe run and fitments is 25% of that hydrostatic head difference. [8] principle was not known or explained. Quite a few candidates erroneously
c. the final CO2 content, in g litre-1, of the beer in BBT if the CO2 top described a venturi, not as a meter, but as an injector device as used for
pressure is left applied for a long period of time so that equilibrium is CO2 injection or with steam for thermal vapour recompression.
established given that Henry’s constant for beer at 5°C is 0.968 x 105 Information on accuracy, reliability, cost and applications was missing
kPa mole fraction-1. [8] in all but the best answers, although a pass rate for this question of 69%
was achieved.
Data The final part was on control. Feedback and feedforward control were
Density of beer = 1005 kg m-3 generally well explained with good examples of each. Feedback control is
Acceleration due of gravity = 9.81 m s-2 retrospective whilst feedforward control is anticipatory. Cascade control
1 bar = 100 kPa is where a secondary controller, which is maintaining a parameter for
Atmospheric pressure = 101.35 k Pa example steam flow, has its setpoint adjusted by a primary controller
Relative molecular weight of CO2 = 44 which might be looking at the outlet water temperature from the calandria.
Relative molecular weight of beer assumed as 18. Ratio control measures and adjusts one fluid, say, at a fixed ratio
(adjusted by the setpoint) to the parameters of a second fluid. Examples in
In tackling any calculation question it is important for candidates to brewing are high gravity beer dilution with deaerated liquor and hot and
realise that getting the right arithmetic answer to part of the question cold liquor mixing at mashing-in.
probably only accounts for one mark. The Examiner is looking for
methodology and explanation in arriving at an answer. All workings
should be shown so that, in the event of the answer being wrong, marks Question 10
can be given for correct method. What factors are important in the selection of suitable primary and
A lot of the answers to Question 8 demonstrated the folly of not starting secondary refrigerants for use in breweries? Name two examples of
the calculation with the full Bernoulli energy balance equation, Many each. [4]
candidates overlooked the pressure difference between the BBT and filler Explain, with the use of diagrams, the basic principles of operation of
bowl and jumped straight in to calculate the pump power requirement on a closed circuit vapour compression refrigeration system. [8]
static head alone, or at best static head plus friction. This is a common Explain why and where in the refrigeration cycle superheating and
mistake since candidates remember from textbooks that pump power po = sub-cooling of the refrigerant are important. [2]
Q Dh r g and take Dh to be the static head difference. But the Dh in this A refrigeration plant is used to extract 56,000 kJ h-1 from a maturation

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cold room. If the condenser and evaporator pressures of its primary required are similar to primary refrigerants - non-toxic, non-
refrigerant are 1 and 10 bar absolute respectively and there is 20°C of inflammable/explosive, non-corrosive, cheap and readily available.
superheat prior to isentropic compression, calculate the mass flowrate The closed circuit vapour compression diagrams were presented either
of the refrigerant and the coefficient of performance of the as P-h/T-h diagrams or plant flowsheets, or in better answers, both. The
refrigeration plant. [6] biggest omission was not showing the refrigerant flow direction with a
flow arrow. The sequence was well described in most answers with just
A Mollier (pressure-enthalpy) phase diagram for the primary refrigerant is some confusion as to which parts were isobaric, isenthalpic or isentropic.
attached at the back of this paper. On subcooling and superheating, answers were imaginative but often not
A good primary refrigerant is a fluid with a high latent heat that will correct. Superheating after evaporation is an essential safety margin to
evaporate at the required “cold” temperature and condense using ambient prevent damage to the compressor if liquid was to enter. Superheating at
air or water, all at pressures that are reasonably easy to engineer. The the end of compression is a consequence of the isentropic compression
evaporation pressure should be above atmospheric to prevent air ingress. and was not accepted as a valid reason alone for superheating – just
Ideally, they should be non-toxic, non-inflammable/explosive, not ozone- because it happens. Subcooling of the liquid refrigerant after condensing
deleting or give rise to greenhouse gases, non-corrosive, cheap and readily creates a higher liquid fraction prior to evaporation and hence a higher
available. Examples such as ammonia, CFCs, HCFCs, hydrocarbons refrigeration effect for the same refrigerant flow rate and energy input –
show that it is not easy to find all these properties in one fluid! CO2 is hence higher COP.
perhaps one of the safest primary refrigerants, but pressures are high and The calculation required reading of the enthalpies from the Mollier
hence costly to engineer. diagram and the most common error made was to take the superheat
Quite a few candidates did not differentiate between primary and temperature as 20°C (293K) and not as “20° of superheat”, which is 20°C
secondary refrigerants, but the requirements are quite different. above the saturated vapour temperature leaving the evaporator. The
Secondary refrigerants do not change phase and need a high specific question was not ambiguous, but this mistake was not heavily penalised
heat to give good heat capacity. Usually they are based on water (good and marks were awarded if candidates proceeded then to use the
specific heat, cheap and abundant!), with chemicals added to depress the enthalpies correctly in calculating the refrigerant flow rate and the COP.
freezing point below the evaporator’s temperature. Such chemicals are
propylene glycol, calcium chloride, industrial methylated spirits, but not
ethylene glycol which is too toxic for food use. Their other properties Brian Eaton – July 2008

DIPLOMA IN DISTILLING EXAMINATION 2008 structure are. However, all candidates rightly regarded the former as rele-
vant to the answer. However, both parts of the answer had to refer to bar-
The examination attracted 32 candidates, mostly for only one module. ley, not the final malt. As one example of the distinction, ethyl carbamate
Two candidates sat and passed two modules, and one sat all three, achiev- potential is a property of the barley variety, but NDMA is produced during
ing Distinction grade and the Worshipful Company of Distillers award kilning and therefore irrelevant to question 1. I was disappointed to see so
Another 5 gained the Diploma in Distilling by passing the 3 modules over many candidates not quoting actual values when writing about such
2 or 3 years. This year there was a 100% pass rate over the three module important properties as moisture and N content and minimum corn size,
examinations, although a few candidates scored only marginally above the implying that they did not know.
pass mark. As usual, the average marks were similar for all three modules:
64.4%, 62.4% and 61.0% respectively for modules 1, 2 and 3. Question 2
I have only a few comments which apply to the examination as a whole. Discuss the basic principles of the design and operation of one type of
This year there were several instances of candidates being unable to com- malt kiln. [10]
plete the final question. While ignorance of the topic was a possible rea- Give an account of the changes which take place in the malt.during
son, I suspect that running out of time was more likely. Each module has a kilning, and explain why these changes are so important for the mash-
3-hour examinatiion, with a choice of 6 questions from 8, i.e. 30 minutes ing process. [10]
each.
Even if that is not enough to answer a question as completely as you Question 2 was answered by 15 candidates. Whichever design of kiln was
would like, a reasonable attempt at all 6 questions will almost certainly chosen, all answers showed a satisfactory understanding of its operation. I
score better than spending more time on 5 and having little or no time to was surprised by the absence of an explanatory drawing from some
answer a sixth. Although most of the examination scripts had neat hand- scripts, and it was sometimes unclear where the first half ended and the
writing and drawings, sadly there were some where presentation left much second part began. A properly labelled temperature v moisture graph
room for improvement. In both this report and on numerous previous demonstrating drying rates would also have been helpful, but was absent
occasions from the poorer answers. However, all candidates scored at least a pass
I have advised that drawings are marked according to quality. While mark.
there is no deliberate deduction of marks for poor handwriting, that could For the second part of the question, many changes take place in malt
happen by default if I am unable to decipher scribbles that may or may not during kilning, but not all are relevant to the mashing process (although
be the correct information. Otherwise, comments and advice appear in the not stated in the question, both grain and malt distilleries were assumed to
section dealing with the particular question which caused my approval or be understood). Limiting the inevitable reduction in enzyme activity dur-
annoyance. ing kilning, by drying at relatively low temperature in a rapid air flow, is
particularly important for grain distilling. Since development of
Module 1 – Materials and Wort melanoidins is associated with high temperatures, colour is a useful indi-
cator of excessive heating. This is equally applicable to both grain and
Question 1 malt distilling malts, whose laboratory extracts should be essentially
Summarise the desirable characteristics of barley for malting. [5] colourless. Explanations of peating and nitrosamine formation were
Explain why three of these characteristics are so important in assess- included in some answers and also accepted as relevant because of their
ing the suitability of barley for production of a malt for a malt whisky effect on the wort, even though they do not influence the actual mashing
distillery. 3 x [5] process.

Sixteen candidates sat Module 1; all chose question 1, mostly as their

first answer, and all but 2 passed. Quality varied from an excellently pre- Question 3
sented summary of an extensive list of barley characteristics (more than I With the aid of a flow-sheet diagram (sketches of the actual plant are
had expected) to only moderately successful attempts to remember what not required), explain briefly the function of each item of equipment
is important to a maltster. To be strictly accurate, many of the desirable between the malt storage bin and entry of milled malt to the mash tun
properties (e.g. screenings, and nitrogen and moisture content) are factors of either a grain or a malt whisky distillery. [20]
influenced by cultivation and harvest and not really characteristics of the
actual barley, whereas attributes such as 1000-corn weight and endosperm Various answers were possible for question 3 according to the type of dis-

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tillery and whether green or kilned malt was used. Essentially a good (c) its relevance to whisky quality. 4 x [5]
mark required descriptions of not only the mill and Steel's masher (if Only eight candidates attempted question 6, perhaps deterred by such a
used) but also the equipment for removal of dust, stones and metal, and long question. However, only a brief account of the three specified fac-
weighing, in the correct sequence. All 14 answers competently described tors was expected for each of the four treatments. I had intended "dem-
the plant. Perhaps inevitably, some were more detailed than others but all ineralisation" to imply removal of hardness salts by ion exchange and
comfortably exceeded the pass mark. "selective ion removal" the precipitation and subsequent removal by filtra-
tion of soluble iron and manganese. It became obvious that some candi-
dates were accustomed to different nomenclature, but appropriate treat-
Question 4 ments for the situations they described were accepted as correct. The two
Sketch the molecular structure of the component parts of the starch fail marks were for more serious reasons of confusing the effects of organ-
granule and how they are arranged in the granule's structure. Using ic and inorganic impurities, and the required treatments; otherwise the
these diagrams, explain the enzymic activities involved in the hydroly- section on activated carbon for removal of colour or flavour taints caused
sis of starch and how their action is influenced by swelling and gela- no problems. Since treatment for both grain and malt distilleries was spec-
tinisation of the granule during mashing. [20] ified, it was necessary to mention that boiler additives to prevent sludge
must not cause a flavour taint of the steam for injection into cookers and
In previous years most candidates have avoided biochemistry questions, stills.
so it was a pleasant surprise to find 14 answers to question 4 on hydrolysis
of starch. Marks varied widely according to the clarity and accuracy of
sketches of molecular structure, and evidence of understanding of the Question 7
enzymic reactions. Two candidates failed; a contributory factor was that With the aid of a diagram, explain the operation of a "biofilter" for
they were among the four who made no comment on the importance of treatment of distillery effluent and discuss the effectiveness of the unit
swelling and gelatinisation to amylolysis, despite specific mention of for reducing BOD for discharge to a river. [8]
these events in the question. A distillery with access to a municipal "activated sludge" plant may
choose to discharge process effluent to the sewer. Sketch and explain
the operation of that type of effluent treatment, and discuss briefly the
Question 5 advantages and disadvantages to the distillery. [12]
Draw the essential features of typical equipment for pressure-cook-
ing of maize or wheat for grain whisky distilling and describe the It was obvious that only two of the four candidates who attempted ques-
operation of the cooking cycle (an explanation of subsequent cooling tion 7 understood the activated sludge process. The other two answered
is not required) [12] only the 8-mark biofilter section, insufficient to attain a pass mark for the
Describe briefly, including comment on advantages and disadvan- whole question. Although few Scottish distilleries have access to a local
tages, one alternative method for preparing the cereal for mashing.[8] authority activated sludge treatment plant, the process appears in the syl-
labus. One of the important advantages is its ability to process a high BOD
The first, main, part of question 5 concerned the standard batch pressure- load of distillery waste water diluted by the much greater volume of rela-
cooking process. Therefore I expected both a description of the proce- tively low-BOD domestic effluent.
dures of one cooking cycle and a drawing showing at least the essential
stirring gear, safety valve (surprisingly, omitted from many drawings),
pressure gauge and valve for venting off air, as well as indicating how the Question 8
grain, water and steam are added and the cooked slurry is discharged. The Describe the design and operation of the Friabilimeter and discuss its
11 answers ranged from a bare pass in this section, to excellent. value, or otherwise, in the analysis of malt. [14]
Subsequently, candidates could discuss the advantages and disadvantages What are the implications of an unacceptably low result of the
of either lower-temperature processing of milled grain or continuous pres- Friabilimeter test? [6]
sure cooking as the shorter second section. Unfortunately one did not
answer that second part, and failed in question 5 as a result. Question 8, on the friabilimeter, was chosen by 15 candidates. Answers
varied in quality from a bare pass (partly due to the absence of a drawing
of the machine) to almost full marks. Everyone was obviously aware of
Question 6 the operation of the equipment and the value of the results, provided other
The following processes could be required for water used in grain and data are considered as well. However, I was surprised that only one person
malt whisky distilleries: demineralisation, selective ion removal, acti- mentioned the value of the friabilimeter as one of the few (necessarily
vated carbon treatment, boiler feed water treatment. rapid) quality checks possible before unloading a delivery of malt.
For each, explain briefly
(a) one reason why the treatment could be necessary,
(b) how the procedure is carried out, and Iain Campbell July 2008

Module 2 – Fermentation, Distillation and Maturation Question 2

Explain the formation of esters and higher alcohols during fermenta-
Question 1 tion by yeast. [14]
Describe, both in words and by a series of sketches showing the prin- In the context of the limited possibilities for variation within the
cipal organelles, the growth of a yeast cell over one generation cycle. Scotch whisky regulations and similar restrictions elsewhere, explain
[20] how changes in fermentation conditions affect the amounts of these
compounds in fermented wash. [6]
Question 1 was answered by 11 of the 14 candidates sitting this examina-
tion; 8 answers scored good to excellent marks. The other 3 failed for not Question 2 was another biochemistry question chosen by most of the can-
explaining cell reproduction. Since the question concerned the growth didates. Of the 10 answers, all but one competently explained the involve-
cycle, the most important parts of the answer were the development of the ment of keto acids and acetyl CoA in higher alcohol and ester formation.
bud, division of the mother cell's nucleus and transfer of one of these Some answers included a more thorough account of the Embden-
nuclei into the bud. Of course a single accurate sketch of the organelles of Meyerhof pathway than was really necessary. Of course that detail was
a fully grown cell deserved some marks, but did not fulfil the requirement appreciated, but I was happy to accept a basic outline as far as pyruvate,
for a series of sketches illustrating the principal stages of the growth cycle the starting point of the various metabolic activities related to the answer.
from bud initiation to the separation of the fully grown bud. Even a good Those candidates who supplemented their descriptions with formulae of
drawing of a yeast cell and competent explanation of the function of the the compounds concerned were generously rewarded. Although variation
organelles scored badly when the growth cycle was not mentioned. in fermentation conditions should be avoided in distillery practice, for the

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purposes of the short second part of the question, discussion of effects of an acceptable final part of the answer, a more substantial assessment did
altered pitching rate or temperature was certainly expected. Most answers not receive any more marks.
provided that information, often in an informative tabular form. Wort aer-
ation, variation in wort composition by mashing problems, and even use
of different yeast strains, were also suggested by some candidates and Question 6
accepted as fair comment. Explain how "cold feints" and "hot feints" are produced in continu-
ous distillation of whisky. Describe how they are recycled, and treated
if necessary, to minimise loss of ethanol from the still system but
Question 3 maintain the quality of the spirit. [20]
Explain the difference between "viability" and "vitality" as applied
to pitching yeast, and describe one method each for measurement of All answers to question 6 were also of a high standard, and since it is
these parameters. [12] unlikely that all 11 candidates work in grain distilleries, I deduce that staff
of malt distilleries are now taking seriously the requirement have a good
Comment on the value of viability and vitality tests in general, and knowledge of continuous distillation practice. Although not specifically
also of the two specific methods you have described, for assessment of requested, I hoped that explanations of sources of cold and hot feints
the quality of pitching [8] would be clarified by sketches of the relevant parts of the still system. I
was pleased to note that all answers included some kind of sketch, but a
Everyone answered question 3, showing a good understanding of the prin- few in the style of Picasso were not really an asset. However, most were
ciples of viability and vitality tests on yeast, although one candidate left carefully drawn, as I have requested in many previous reports. The words
insufficient time to achieve a pass mark. In question 2 there was no specif- ". . . maintain the quality of the spirit" at the end of the question particular-
ic advice on the amount of detail required, hence my favourable comment ly applied to hot feints, and specifically the possibility of aeration to elimi-
above on more than expected about Embden-Meyerhof. However, in nate ethyl carbamate and volatile sulphur compounds. For cold feints, i.e.
answering question 3, some candidates tried to impress by providing a full either condensate from various top condensers or out-of-specification
list of possible viability and vitality tests rather than the requested one of spirit, re-distillation is necessary, and because of the high alcohol content
each. There were no marks for that irrelevant information, even though it (a fact which some candidates omitted to mention) the feed rate must be
was always factually correct. That unnecessary effort would have been carefully controlled to avoid de-stabilising the still. In any case, control-
better expended on writing useful information elsewhere. ling the recycling rates of both hot and cold feints to maintain steady state
For only 8 marks, it would be unreasonable to expect "comment on the conditions in the stills is important for spirit quality.
value of viability and vitality tests in general" to include details of all pos-
sible methods. I wanted only a brief discussion of both types of test being
required to predict an efficient fermentation. One of the better answers Question 7
claimed that a vitality test should not be needed for fresh commercial dis- Explain the concepts of additive, reductive (or subtractive) and pro-
tilling yeast. I agree, but would argue that it is a useful test to decide ductive processes during maturation and describe two examples of
between using or throwing out yeast after longer storage. Most answers each type. [20]
mentioned methylene blue or alternative redox dyes which are widely
used to measure viability (i.e. ability to reproduce) but they actually indi- All candidates answered question 7, and all but one passed. Some were
cate metabolic activity. Not all answers discussed the implications of that confused about the distinction between additive and productive processes,
discrepancy. both of which add new congeners to the spirit. According to well-estab-
lished terminology, "additive" means extraction into the spirit of existing
compounds in the structure of the cask, and "productive", generation of
Question 4 congeners by chemical reaction (e.g. esterification, hydrolysis, oxidation)
Bioluminescence and the polymerase chain reaction (PCR) are two within the maturing spirit. Only two examples of "additive" were required
possible methods for rapid detection of bacterial and wild yeast con- from the lignin degradation compounds, tannins, sugars, lactones, etc
taminants of pitching yeast and supposedly sterilised equipment. present in charred wood.
Explain briefly the principle and application of each of these tech- Even if a lignin aldehyde was mentioned in the context of additive reac-
niques for these purposes. [20] tions, subsequent changes of that compound to acid and ester were accept-
able for "productive", but of course there were numerous other possibili-
Since the principles of both bioluminescence and PCR required extensive ties. Although specialists in maturation chemistry would rightly disagree,
explanation, most of the marks for question 4 were allocated to these I simplified the question by requiring only two examples of removal of
explanations, and one example each of detecting the two types of contam- congeners from the maturing spirit, whether by absorption or evaporation
inant was sufficient. It was obvious that only those with a good under- (subtractive) or by chemical reaction (reductive). Incidentally, evaporation
standing of these topics had chosen to answer the question. The three of ethanol and water, used as an example by several candidates, was not
answers competently explained the principles of the methods, and the pos- accepted as a genuine subtractive process. There were many other com-
sibilities, and the limitations, of their application. pounds to choose from, acetaldehyde and dimethyl sulphides probably
being the most important. Since lignin derivatives and tannins have com-
plex structures, I was prepared to be lenient over minor inaccuracies, but
Question 5 was impressed by the number of scripts showing the chemical formulae
Describe in detail the cleaning requirements for mashing and fermen- correctly.
tation vessels of malt and grain whisky distilleries, and the cooking
vessels of grain distilleries. Include an account of suitable materiials
for these purposes. [20] Question 8
Define ‘balanced’ and ‘unbalanced’ operation of wash and spirit stills
Question 5 was much more popular, answered by 12 candidates. Although and discuss briefly the advantages and disadvantages of each system.
all were good answers, I was really impressed by the detailed descriptions [8]
in some scripts, e.g. on the different procedures for wooden and stainless Draw graphs of the approximate values of the volume (expressed as a
steel washbacks. An important part of a good answer was the distinction percentage of the actual charge volume as 100%) and alcohol content
between cleaning and sterilisation, the latter being necessary only for fer- in the spirit still charger vessel (a combined low wines/feints receiver)
mentation vessels in the equipment specified in the question. Being oper- over an 8-hour period when:
ated at high temperature, mash tuns and cookers require only routine (a) both stills operate once on an 8-hour cycle. [6]
cleaning, to prevent accumulation of soil which could support growth of (b) the wash still has two 4-hour runs and the spirit still has one 8-
micro-organisms which produce off-flavours. Therefore the account of hour run. [6]
suitable cleaning materials had to distinguish between just the removal of
soil, and the additional requirement to sterilise the cleaned surfaces where Eight candidates answered question 8, and defined correctly the concepts
appropriate. Assessment of effectiveness was not included in the question, of balanced and unbalanced distillation. Unfortunately three candidates
so although a brief mention of that aspect of cleaning and sterilisation was did not achieve a pass mark, by misunderstanding what was required for

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the graphical part of the question; indeed some of those who passed were bends, valves, etc as equivalent to the frictional effect of pipe diameter,
also confused in that section. Although the 2-for-1 distillation programme and of course to show an understanding of fluid flow through the two dif-
(b) did not actually have the random effect of truly unbalanced operation, ferent designs of valve.
it gave the opportunity to compare volume and alcohol strength in the
combined receiver vessel with the 1-for-1 programme (a). Obviously pre-
cise values could not be expected, but I was disappointed that so few Question 4
graphs showed the general picture. Basically, for both programmes, the Draw, and briefly explain the function of, the principal features of the
volume graph would show three stages:a rapid increase while both stills equipment for pressure-cooking unmalted cereal for grain whisky
were feeding the low wines/feints receiver vessel, slower while the spirit production, and for energy recovery from the cooked cereal. [10]
still was filling the spirit receiver, and finally more rapid again during col- Using the data below, calculate (a) the initial temperature of the
lection of feints. To be absolutely accurate, there would be a short period water/grain slurry and (b) the weight of steam required to heat a
during run (b) while the second wash still charge was heating up and only batch of 15 tonnes of wheat to 140°C, assuming a perfectly insulated
the spirit still was feeding the receiver, but I did not expect anyone to cooker vessel. [10]
allow for that (I was right!) The alcohol graph (a) would be, essentially, Initial water charge to cooker = 37.5 tonnes
the well-known graphs of wash and spirit still distillations combined, but Temperature of initial water charge = 80°C
again showing no feed from the spirit still during spirit collection, and run Specific heat of water = 4.2 kJ kg-1K-1
(b) of course would have two wash still graphs in succession. Initial temperature of wheat = 12°C
Specific heat of wheat = 1.5 kJ kg-1K-1
Iain Campbell July 2008 Latent heat of condensation of steam at average temperature of slurry
over heating programme = 2256 kJ kg-1

Question 4 was answered by all candidates. As usual, the quality of

Module 3 – Process Technology drawings varied from neat and accurate to abstract, but even distorted
shapes received reasonable marks if all necessary equipment was shown.
Question 1 Most candidates were able to calculate the temperature of the grain/water
Explain the significance of the design of body, neck and lyne arm of a mixture as 71.5°C, but some then used the original 80o of the water rather
spirit still, and the rate of distillation, on the composition and quality than 71.5° in the calculation of steam requirement, obviously losing
of the spirit produced by that still. [20] marks for the inevitable wrong answer. Others, perhaps not trusting their
answer to the first part if it was lower than their own experience, calculat-
Six of the 7 candidates who sat the Module 3 examination answered ques- ed the steam requirements for heating the water and grain separately, also
tion 1. All answers gave competent assessments of the effects of distilla- getting the correct answer 5465 kg. Unfortunately, two avoided the 10-
tion rate and still shape, in particular of the neck and lyne arm, on reflux mark calculation completely and, inevitably, failed.
and therefore on (a) the nature and amount of congeners in the spirit and
(b) the opportunity for reaction between the spirit vapour and the copper
surface of the still. The best answers also mentioned supplementary fit- Question 5
tings to increase reflux, e.g. a ‘purifier’ in the lyne arm, although no one Explain the basic principles of a plate heat exchanger and describe
answer provided a complete list of all possibilities. the heat-transfer implications of operation with co-current and
counter-current flow. [5]
Hot condensate is collected from four points in a distillery and com-
Question 2 bined for use in a heat exchanger. Calculate the temperature and flow
With the aid of appropriate illustration, explain how the spirit vapour rate of the combined stream if the flow rates of the individual water
is fractionated in the rectifier column of a continuous still to produce streams are as follows:
spirit of acceptable quality for grain whisky. [20] (a) 0.5 kg s-1 at 72°C, (b) 1.2 kg s-1 at 82°C, (c) 1.4 kg s-1 at 90°C, (d)
0.8 kg s-1 at 68°C [5]
Question 2 was answered by five candidates; three passed. "Appropriate The combined hot stream feeds a counter-current heat exchanger to
illustration" could include a general drawing of the rectifier, but I expected heat fresh water from 8°C to 70°C. What is the flow rate of cold water
that the graph of the distribution of the principal congeners over the height if the heat exchanger is operated to cool the hot stream to 20°C? [5]
of the column would be an important part of a good answer. That was What is the total plate area of the heat exchanger? [5]
largely true, although one candidate did manage to provide a satisfactory Specific heat of water = 4.2 kJ kg-1K-1
explanation of the separation of congeners without the assistance of the Overall heat transfer coefficient of the heat exchanger = 850 W m-2K-1
expected graph. However it was a general shortage of relevant information
rather than any specific omission which caused two of the answers to All five answers to question 5 gave competent accounts of co- and count-
score a marginal fail mark. er-current heat-exchange systems. Unusually, the calculation part of the
question provided most of the marks, which was unfortunate for the one
candidate who failed. It was especially unfortunate that his/her arithmetic
Question 3 was presented in such a disorganised way that it was impossible to follow
Explain in words and by sketches of velocity profiles in pipes the dif- my normal practice of awarding marks for correct parts of the answer. I
ferences between laminar and turbulent flow. Discuss the relevance of emphasise again that a logically presented calculation, even if ultimately
these two flow regimes in different situations which occur in the dis- leading to a numerically wrong final answer, will be awarded marks for
tilling industry. [7] correct intermediate stages, or for parts that are organised in the correct
Cold wort of density 1060 kg m-3 and viscosity 0.003 kg m-1s-1 flows way. For example, although one candidate calculated the temperature and
through a 50 mm internal diameter circular pipe at a rate of 3.5 kg s-1. flow rate wrongly, subsequent correct calculations from the already-
Determine the mean velocity (u) of the wort in the pipe and determine penalised wrong figures scored full marks for the relevant sections.
the centre-line velocity (uCL) given that: u= 0.5 uCL for laminar flow; u
= 0.82 uCL for turbulent flow. [6]
Explain the concepts of measuring the effect of pipe geometry on fluid Question 6
flow as multiples of pipe diameter and number of velocity heads. As Describe, with sketches, two types of centrifuge which could be used
an example, state whether a gate or globe valve in the fully open posi- for separation of grains-in spent wash of a grain distillery into spent
tion has the higher value, and explain why the difference exists. [7] grains and a supernatant stream for subsequent evaporation. [14]
Comment briefly on the advantages and disadvantages of each type.
The two candidates who attempted Question 3 both scored acceptable [6]
marks. Normally I would consider it would be unfair to comment on only Question 6 was also answered by all candidates The decanter type of cen-
two answers, but in the final part there was clearly a suspicion that my trifuge was the first choice in most of the scripts, but, surprisingly, in two
simple question implied more than I had intended. All I wanted was an answers good drawiings of decanters were scored out in favour of two dif-
explanation of the concept of treating the frictional losses associated with ferent designs of bowl centrifuge. I was unwilling to accept two similar

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bowl centrifuges as different designs. However, they were well drawn, and Question 8
I did, very exceptionally, make an allowance for the good quality of the Explain with the aid of a drawing how a wash still and its shell-and-
scored-out material, which was clearly to candidates' advantage in show- tube condenser are protected from damage by accidental internal
ing their knowledge of different types of relevant equipment. pressure changes. Give a brief description of these safety devices and
their operation, and the likely causes of such pressure variations. [8]
Describe, also with appropriate drawings, the equivalent problems
Question 7 and protection for the plates of the two columns of a continuous grain
Describe the basic principles of design and operation of instrumenta- whisky still with grains-in wash. [12]
tion for the following measurements:
(a) fermentation temperature. Only four candidates attempted question 8. Three passed, although in
(b) volume in a low wines receiver vessel, their answers the safety features of only one of the pot or column still
(c) flow rate of spirit from continuous still to receiver vessel and were answered well, presumably reflecting practical experience of only
(d) alcohol content of reservoir vessel for cask filling. one system. However, possible causes of pressure variation were not as
Choose a different type of instrument for each measurement. 4 x [5] fully discussed as I had hoped. The three safety devices expected for a pot
still were the air and anti-collapse valves of the still itself and the tail pipe
I had assumed it was obvious that question 7 referred to the design and of the condenser. For individual column plates the seal pots and safety
operation of electronic instruments for temperature and volume. But I valves performed somewhat similar functions, but the complete still also
have to agree that a mercury thermometer and a dipstick are instruments, requires a safety valve. Drawings were an important part of the answer,
and thanks to a detailed explanation of their use were accepted, as was a hence the uneven distribution of marks between batch and continuous dis-
similarly detailed explanation of the use of a hydrometer for alcohol tillation.
measurement. Otherwise the expected vibrating tube system was
explained, and all 5 candidates described modern flow meters. This was
the best-answered question of the paper, all with clear passes. Iain Campbell – July 2008

DIPLOMA IN PACKAGING EXAMINATION 2008 Module One

14 candidates sat this unit, with two candidates having Recognised Prior
Examiners Summary Learning exemptions on Unit 2 based on demonstrated evidence of their
2008 was the pilot year for this examination, and only Modules One and previous qualifications. Overall a good pass rate of 71.4% was achieved,
Three were launched this year, with Module Two available to candidates with two candidates gaining Grade B (14%), four candidates gaining
from October 2008 for the 2009 exams. Grade C, and four candidates gaining Grade D (28%).
The results from both Modules have given an overall Diploma in
Packaging pass rate of 79%, with particularly pleasing results in Modules Module 1 : Unit 1 – Packaging Theory and Materials
Three which had a 100% pass rate. Going forward this qualification will
hopefully ensure that the industry is able to recognise those candidates (a) Assignment
who can demonstrate their knowledge and understanding of the packaging a. Select a non primary packaging material with which you are
formats which are seen or used by both customer and consumer. Each familiar. Obtain the current specification used to purchase this
Unit of the Diploma in Packaging was assessed in three components, viz. material.
assignment (35%), short answer questions (30%) and one long answer b. Investigate whether this material is delivered within this
question (35%). The Unit scores were then combined to give an overall specification and how it is maintained within specification from
mark and grade for the Module. As with the Diploma in Brewing, an delivery to point of use on the packaging line.
overall pass in the Diploma is only awarded when all three Modules have c. Discuss the appropriateness of this specification and give proposals
been successfully completed. as to what can be done on the packaging site to ensure consistency
Whilst detailed commentary for each unit section is given in the report and minimise failures on the packaging line.
below there were some common themes which need to be brought to the d. Discuss how the required specification can be achieved by the
attention of candidates. manufacturer of the material and what issues that manufacturer may
In the Assignment, the key areas looked for were relevance to brief, have.
quality of discussion, range of references accessed and appropriate use of
them, extent of analysis and evaluation, comment and originality. It is This was the first assignment. 2,500 words were given as a guide to the
important to ensure that the submission answers the assignment questions, length of assignment – with the one which only had 1150 words not
with a good answer being to the point with sufficient depth of discussion. surprisingly lacking information.
The assignment should include references in order to show that the Good assignments followed the brief and gave a good description of the
candidate has read round the subject. Once used these should then be cited selected non-primary material, and how it was used on the packaging line.
and listed using the Harvard referencing system. A guide on this is Most people selected a corrugated carton. Poor answers either selected a
provided to all candidates, and should be used – something which was not primary package, a carton not used for beer or a mixture of secondary
clearly demonstrated throughout the assignments by a number of packaging. Candidates should also be careful in not going outside the
candidates. brief by, for example, giving a detailed description of carton manufacture
The short answer question is based on 15 multiple-choice questions and then not having enough space to complete the main brief.
which are designed to test the candidate’s breadth of knowledge of the The assignment needed a challenging review of issues which arose
overall syllabus. It was pleasing to see that this was generally well when using the selected material from purchase to storage to use on the
attempted in most Units, and calculation questions demonstrated a machine. Good answers highlighted damage issues in the delivery chain
candidate’s ability to apply their knowledge into a practical workplace and the importance of the correct storage conditions and time in storage in
situation. order to achieve a good quality material (mostly board) on the machine.
The long answer question section requires the candidate to choose to However, most assignments would have benefited from more investigative
answer one question from two. These questions are set at a similar level to work, analysis and a clear presentation of those findings.
those used in the Diploma in Brewing and are designed to test a
candidate’s in depth knowledge of a particular area of the syllabus. These Jeremy Browne, July 2008
questions tended to show which candidates had only a superficial
knowledge of their chosen subject, whilst good candidates were able to (b) Short answer questions
provide excellent answers. The results in this section ranged from a highest score of 11 correct
answers to a low of 6 correct. Calculation questions were generally
answered well by most candidates, although it was clear from some of the

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factually based questions that candidates had not studied the learning Module 1 : Unit 2 – Beer Appreciation
material in detail. This paper also showed up a general weakness in
candidates’ knowledge of how packaging materials are manufactured, and (a) Assignment
their individual properties and uses. a. Identify the key parameters within a product specification, which
should be analysed at each stage of the brewing process to enable a
(c) Long answer questions product type of your choice to be produced consistently.
All 14 candidates chose to answer question 2, with no answers submitted b. For each stage of the brewing process up to bright beer tank,
for question 1. The majority of candidates provided a reasonable level of identify which of these parameters can be influenced by that stage.
answer to the question, although there were two very poor answers, and Also explain how each stage can influence the consistency of the final
one outstanding one. product.
c. Identify how the key specification parameters may be influenced by
the brewing process, including dilution, and how this relates to the
Question 1 beer in final package.
a. Describe the manufacturing processes required for the d. Compare your findings with the current specification and analysis
manufacture of a batch of kegs, from order placement through to schedule.
delivery to the production site. [12] Recommend and justify any changes which could be made.
b. Write brief notes on the quality assurance steps which should be
observed throughout the manufacturing process. [4] It is important to ensure that the submission answers the assignment
c. List any additional precautionary steps required when a new batch questions. Good answers need to be to the point with sufficient depth of
of kegs is first used on a production line. [4] discussion.
The references should show that the candidate has read round the
It was disappointing that no candidates felt confident enough to attempt subject. A good understanding of the Brewing Process is required. This
this question. The manufacturing processes used to produce key primary was not demonstrated by several candidates who demonstrated only a
packaging materials are an underpinning element of this unit, and this superficial understanding. Poorer answers concentrated on describing the
should have been a section which was clearly understood. A good answer process and some of the plant and did not discuss how key specification
would have covered the order specification for the kegs before going on to parameters were influenced by the different stages of the brewing process
describe the keg manufacture process in detail. Delivery and quality through to final package. Similarly findings were not compared with the
assessment areas should ten have been covered, including any trials / current specification and analysis schedule.
segregation that should be done on and off line before the kegs are placed Appendices quoted in the text need to be enclosed with the submission.
into routine production.
Eric Candy – July 2008

Question 2
a. Provide a table of information to explain the functions and basic (b) Short answer questions
properties of primary, secondary and tertiary packaging materials, The results ranged from a highest score of 13 correct answers to a low of 7
along with examples of each material. [12] correct.
b. Selecting one material explain briefly how it provides the required A few questions, somewhat surprisingly, caused several candidates
consumer information. [4] some problems to answer. For example, it would be expected that
c. List the relevant checks undertaken on the production line which packaging candidates would know that the main objective for filling the
are required to validate the consumer information. [4] headspace of a bright beer tank is to minimise the rate of dissolved oxygen
pickup, rather than prevent loss of carbon dioxide; also that the best
Most candidates displayed a reasonable knowledge of the split between conditions for encouraging carbonation are low temperature and high
primary, secondary and tertiary materials, although there was a wide pressure. Finally, it was somewhat disappointing that so few candidates
variation in the standard of information provided about the function and knew that brewing yeast reproduces by budding.
basic properties of each. The best answers given were in a clearly detailed
table and listed a number of examples of each type of packaging material (c) Long answer questions
along with their functions and basic properties. The functions of each Five candidates elected to answer question 1, with 7 choosing question 2.
packaging material should provide a clear description of what the material In the main, the answers to question 1 were of a higher standard, although
contributes to the pack, with the properties of the material describing how 2 candidates provided good answers to question 2.
the material does this. It is important for candidates to have an
understanding of a wide range of materials – with poorer answers only
providing one example of packaging and one or two word descriptions. Question 1
Two candidates obviously mis-read the question and wrote answers about a) List the types of substances which can cause the production of non-
marketing and technical aspects of packaging – without covering the areas biological haze in beer. [5]
requested in the question. b) Describe the production procedures which may be employed to
The section on consumer information was generally well covered with stabilize beer against the formation of such hazes. [15]
candidates listing the mandatory information such as best before date, and
legal information. Those candidates who also included the advisory Most candidates were able to identify the most likely sources of haze
information – such as number of units, health advice – gained a higher material in beer, with the correct emphasis on the role of oxygen in
mark overall. oxidising polyphenols and interactions between polymerised polyphenols
The final section of the question required a candidate to list the checks and polypeptides leading to chill haze and permanent haze formation.
to validate the consumer information. In general this was not as well Also noted was the potential for haze particles resulting from collapsed
answered, and required a candidate to look at the line based quality checks foam from denatured polypeptides or hop acids (especially reduced
e.g. ABV, volume and correct use of materials. The better answers also products, like tetra-iso-α-acids). Some candidates also listed calcium
explained how the checks could be undertaken and the frequency they oxalate, filter powder let-by or even unfiltered PGA (for foam
would expect to do them. Too many candidates failed to link the checks to enhancement). Most candidates, however, remembered to include
the consumer, and there was no recognition of how the checks can link to carbohydrate hazes, such as β-glucans and pentosans or even α-glucans
supplier vendor assurance schemes. (residual starch or yeast autolysis products such as mannan).
There were some good answers for the second section, with candidates
describing all the control points throughout the brewing process to
Ruth Bromley – July 2008 minimise the risk of carry over of potential haze forming material into
finished beer. This started with selection of raw materials, optimising
brewhouse conditions (with adequate calcium ions present to ensure pH
control and precipitation of calcium oxalate), especially boiling and trub
compaction and removal and use of kettle finings. Ensuring good yeast

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separation and temperature control post fermentation, followed by very achieving the desired microbiological and flavour stability.
low temperature conditioning (brewing at high gravity helps here) are also f. Using the information gathered investigate how your installation is
key. Filtration at as low a temperature as possible, with all process designed and operated, and identify whether the design and control
additions pre-filter (except PGA, which therefore should be micro-filtered measures are adequate and, if not, recommend any changes.
separately) is also important. Surprisingly, a few candidates omitted to
describe the use of silica gels or tannic acid or papain to remove sensitive Nearly 80% of the candidates selected tunnel pasteurisation. For this
proteins/polypeptides or PVPP to remove polyphenols, which are, of assignment it was extremely important to follow the brief. Some
course, major factors to be involved in stabilising beer against haze candidates just gave a generic description on how the pasteuriser worked
formation! All candidates stressed the importance of good control over and this was not enough to earn high marks.
dissolved oxygen pick up during all stages of beer processing and Good assignments gave a description of the process with clear
packaging. diagrams and process parameters for operation. This was followed up
with an analysis of the operation and comments on the process as a result
of the findings. It is important that the process is understood. Poorer
Question 2 assignments showed a lack of understanding of the process, and did not
Describe the factors that can affect beer flavour stability during include any investigative work into its operation.
prolonged storage of packaged beer. [20] One part of the assignment asks about other control measures that are
required to prevent any subsequent damage to the packaged product.
All candidates were well aware of the importance of dissolved oxygen Many candidates missed the need for oxygen control which is what this
control during beer processing and packaging in relation to resistance to part of the assignment was looking with regard to flavour stability.
development of stale flavour characteristics during storage of packaged The appendices varied considerably. Appendices should only be used
beer. Also, the need to ensure package integrity (crown seals, can seams, to illustrate or re-enforce a point. Copying pages out of manufacturers’
keg spear seals) was discussed, some candidates noting the value of manuals or internal documents are not required and are not encouraged.
oxygen scavenging crowns for bottles. The risk of microbiological Good appendices will include diagrams and/or data collected which
contamination as a consequence of poor package integrity was also support the assignment.
commented on. However, too much emphasis was given to ensuring that
pasteurization or sterile filling had been carried out correctly. Clearly, this Jeremy Browne, July 2008
is important for good practice, but of little relevance to a discussion on
prolonged storage of packaged beer, since any significant microbiological
contamination present at zero time will develop very quickly in relation to (b) Short answer questions
shelf life. The results ranged from a highest score of 10 correct answers to a low of 5
Very few candidates commented on the necessity for oxygen barriers correct.
for PET bottles and again there was little commentary on the actual Whilst the majority of the papers showed a general based grounding in
flavours associated with staling (such as papery, bready, cardboard small pack filling operations, there were some areas which were well
characters and increased sweetness) and no information on the potential known, and others which were much weaker. In general pasteurisation
reactions involved. and principles of small pack line design seemed to have been well learnt,
Most answers discussed the benefit of low temperature storage of and basic calculations were again well answered. However this paper
packages and identified some of the practical difficulties associated with showed a number of weakness areas with candidates not able to apply
widely varying ambient temperatures, especially the risk of freezing. their calculation in practical situations.
Some commented on humidity and the risk of crown rusting, which could
affect flavour for customers who drink directly from the bottle! (c) Long answer questions
Others also commented on other potential risks to flavour from package Question 1 was answered by 9 of the candidates, with the remaining 5
defects, such as poorly applied or poorly cured lacquers in cans and chosing to answer question 2. Both questions generally had average
aluminium kegs. results, with answers to question 2 being slightly better structured and
Several candidates noted the potential for light striking reactions in hence scoring slightly higher marks.
unprotected clear or even green bottles, and the use of reduced hop
products to avoid this flavour development.
No candidates mentioned flavour developments associated with bottle- Question 1
conditioned products and really good answers would have noted that a. Describe the processes required to fill an empty glass bottle from
bitterness tends to be reduced on prolonged storage, mainly due to the loss the point at which it enters the filler to the point at which it is
of the trans-iso-_-acids. discharged from the crowner. [8]
b. List the checks required, from bottle infeed to pasteurizer
David Taylor – July 2008 discharge, to ensure the finished product will meet relevant food
safety legislation. [4]
c. Produce a table of the key analytical checks undertaken at the
Module 1 : Unit 3 – Beer Preparation, Micro bottle filler. Include the reason for the check, the frequency and the
Stabilisation for Packaging including Small Pack expected range of results (including any relevant units). [8]
Filling Operation
The descriptions provided for bottle filling ranged from poor to excellent.
(a) Assignment The most complete answer detailed the whole filling process including
a. Draw and describe a microbiological stabilisation installation cam movements, gas pressurisation sequences, vent tube information and
(plate pasteurisation, tunnel pasteurisation, sterile filtration) on a bottle movements. However a number of candidates ignored both the
packaging line of your choice including associated utilities. jetting and crowning processes and so lost marks as a result, with only a
b. Obtain the design specification and manufacturer’s recommended limited number of answers covering missing crown detection systems.
operating conditions for this system. The checks to meet food safety legislation should have been covered by
c. Research this method of microbiological stabilisation and produce following the process through the front end of the bottling line. Most
a document describing how, when using this type of microbiological candidates covered checks for contents and ABV, with some limited
stabilisation, infected product could still be found in the final descriptions of foreign body checks at the rinser and EBI. Risk from CIP
package. residue was also mentioned, however microbiological contamination of
d. What control measures are required to prevent this happening with the pasteuriser and legionella checks were generally missing from most
minimal flavour change? descriptions and only one candidate discussed bottle burst protection
e. What other control measures are required to prevent any sequences.
subsequent damage to the packaged product? Your answer should The table of key analytical checks was generally disappointing with
include a description of the appropriate methods required to ensure candidates identifying the parameters they would test for, but then only
that the chosen microbiological stabilisation method is consistently providing limited details of the reason for, and the frequency of, the test.

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The expected range of results was also limited, and should be an area Question 1
understood by candidates at this level. a. Describe the principles and operation of a CIP system for a non-
sterile fill canning line. [10]
b. List the key design criteria and materials of construction which
Question 2 should be considered for a canning line in order to minimize
a. Describe, with the aid of a diagram, the operation of a tunnel microbial contamination. [10]
pasteurizer, clearly detailing all relevant times and temperatures at
each stage of the process. [10] Neither section of this question was particularly well answered by any of
b. List the routine checks required on a tunnel pasteurizer to ensure the candidates. The first section of the question was looking for a
relevant personnel safety aspects have been addressed. [4] candidate to be able to explain the relationships in the CIP process
c. List all of the key actions and checks required on the pasteurizer, if between time, temperature, mechanical and chemical cleaning properties
a batch of product is placed on hold as a result of under and their effect on soil. This was generally not done, and it was surprising
pasteurization. [6] how many candidates failed to detail what the chemical used for cleaning
was. Most candidates then continued by only referring to the CIP regime
The standard of drawings provided by candidates for this question was for the filler, and generally ignored the cleaning requirements for the
good, with most showing a clear representation of the operation of the buffer tanks, pipework and utilities with a few exceptions.
tunnel pasteuriser with good references to times and temperatures. The The section on design criteria and materials of construction was
descriptions were also generally of a reasonable standard, with good answered with more details, although there seemed to be very little
answers explaining the rationale for regeneration zones, and the links application of the theory to the actual reality of microbiological results
between zones. The best answers covered off exit temperatures of the achieved on a canning line. A good answer would have included aspects
containers, along with the reasons behind this, as well as use of PU of the design including things like sensor positions, pump types and
monitoring devices along with an explanation of how cold spots can specifications, access hatches, pipework design and installation to name
occur in containers. but a few. Some of the better candidates could identify the difference
The second stage of the question was looking for candidates to identify between 304 and 316 stainless steel, but very few recognised the need to
personnel safety aspects, and was not generally well answered. A good use different materials on manually connecting pipework joints.
answer should have included use of PPE, housekeeping, chemical
identification and bunding requirements along with safe operation and
entry systems to allow for maintenance where required. Perhaps the most Question 2
worrying was the lack of reference to legionella monitoring and treatment a. Describe the analytical sampling processes required for a
by the majority of candidates. packaging line of your choice. [10]
For the final section of the question the majority of the candidates b. Explain the different error factors which must be taken into
correctly focussed their answer on the pasteuriser checks – although some account when interpreting the data produced. [10]
candidates did waste time and marks providing long and detailed checks
that they would carry out on the beer in order to determine whether or not Most candidates produced a reasonable answer for the first part of this
it could be released safely. question. A good answer covered off each of the sampling areas in turn –
from bright beer beer through to final package – and detailed the sampling
Ruth Bromley – July 2008 and analysis that was required at each stage. A couple of candidates also
explained why some analyses only happened by exception e.g. bitterness
sampling in bright beer, and this helped demonstrate their understanding
Module 1 : Unit 4 – Quality and Hygiene and application of the process in the real world. The best answers detailed
the timings and frequencies of the sample schedule, as well as the risks
(a) Assignment and reasons behind the samples. Disappointingly only two candidates
a. Describe the quality system in place for a primary packaging linked the samples to their previous reference point – i.e. from bright beer
material used on a packaging line of your choice to ensure that this to holding tank. Very few candidates also mentioned the need to calibrate
primary packaging material does not affect the quality of the finished and check laboratory equipment, and there was no mention of sampling
product. and analysis validation processes e.g. inter laboratory collaboration
b. Provide details of the checks that are currently in place. checks and blind sampling.
c.How could this system be improved towards achieving zero defects? The second half of the question was much less well answered – with
one candidate choosing to ignore it completely. Of the remaining five
It is important to ensure that the submission answers the assignment candidates most listed the issues around operator capability, and the
questions. Good answers need to be to the point with sufficient depth of repeatability and reproducibility of results with in analytical environment.
discussion. The quality of some submissions was most encouraging. Good However most then ignored the use of statistical analysis and trending of
submissions clearly identified the primary packaging material chosen results, sample preparation conditions and threshold factors to name but a
with a discussion which included supplier QC and supplier partnerships. few of the errors that can creep in to the results.
The better submissions entered into the spirit of the assignment by
critically investigating the chosen quality system and identifying where Ruth Bromley – July 2008
improvements could be made and suggesting possible solutions.
Module Three
Eric Candy, July 2008 5 candidates sat this unit, with no candidates having any Recognised Prior
Learning exemptions based on demonstrated evidence of their previous
(b) Short answer questions qualifications. Overall an excellent 100% pass rate was achieved on the
The results ranged from a highest score of 12 correct answers to a low of 8 exam, with one candidate gaining Grade B (20%), two candidates gaining
correct. Generally there was a consistent spread of correct answers across Grade C (40%), and the final two candidates gaining Grade D (40%).
the majority of the questions with only two questions appearing to cause
candidates an issue. The steam requirements for sterilisation appeared not
to be well known amongst candidates, and no candidate correctly Module 3 Unit 9 – Process Gases for Packaging
identified the best graphical method of displaying and monitoring
analytical results. (a) Assignment
a. Draw and describe a carbon dioxide collection system with which
(c) Long answer questions you are familiar.
Question 1 was answered by 8 of the candidates, with the remaining 6 Obtain the manufacturers performance specification for the quality
choosing to answer question 2. Neither question was particularly well of the collected carbon dioxide.
answered, with nearly all candidates failing to score even half marks. Investigate and describe the potential differences between the quality
of the collected carbon dioxide collected against purchased carbon
dioxide.

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Describe the principal components of a carbon dioxide collection Question 2

system and discuss the function of each. a. From production to the point of use, describe with the aid of a
b. For a beer supply system of your choice state the gas/ gases used diagram how compressed air for a packaging department is produced
along with the pressure and temperature conditions used for bright and distributed. Include in your answer typical key components and
beer storage. Using solubility data supplied separately, calculate the operating parameters, describing their relevant merits. Highlight
equilibrium carbon dioxide concentration in the liquid in the tank, appropriate safety requirements. [15]
and compare this concentration with the specifications for the b. List typical uses of compressed air in the packaging department,
product stored in this tank. their differing quality requirements, and how those quality
Comment on the appropriateness of this pressure and temperature requirements are achieved. [5]
regime.
Three candidates chose this question and all passed. The examiner was
It is important to ensure that the submission answers the assignment looking for a detailed description of the components and layout of a
questions. Good answers need to be concise but with sufficient depth of compressed air system along with operating parameters and relative
discussion. merits - that is, answering the question of “why is this component
Good answers should compare the quality of the carbon dioxide necessary?” An example could have been the relative merits of
collected against the agreed specification. This should include looking at reciprocating versus screw compressors – a single compressor for a
non oxygen impurities. packaging department most likely will be a reciprocating compressor,
Part B answers identified some problems with mathematical errors plus while a distributed system for an entire brewery might be multiple screw
use of the wrong conversion factors. It is vital that work is shown as the compressors. Only one candidate chose to discuss safety requirements.
majority of marks are awarded for the approach used rather than obtaining The latter part of the question asked candidates to list uses along with
a mathematically correct answer. The later is however important to your differing requirements, for instance air quality for conveyor guides versus
company as mathematical errors can lead to wrong decisions being made instrument air.
which could impact on product quality!
Good submissions explored the effects of various temperatures and Tom Shellhammer, July 2008
pressures.

Eric Candy, July 2008 Module 3 Unit 10 – Fluid Dynamics for Packaging and
Materials of Construction

(b) Short answer questions (a) Assignment

The strongest candidate achieved 11 correct answers out of 15 with the a. Describe and draw the beer supply system from bright beer tank to
weakest achieving just 4. filler with which you are familiar. Include dimensions of pipe
The multiple choice questions spanned the entire syllabus including in diameters from bright beer tank to the point of container fill. Record
some instance short computations. Candidates had most difficulty gas the pressures across the system and estimate the maximum and
quality specifications and mixed results with the computational questions. average flowrates. Include details from the manufacturer’s plates of
All candidates displayed good know of CO2 liquification processes. any equipment in this system.
b. Assess the filling performance of the filler against the
(c) Long answer questions manufacturer’s guarantee with special reference to the stability of fill,
fill height variations and filling rate.
Question 1 c. Obtain the pump curves for the pumps in the system. Stating your
a. Explain by using the appropriate physical relationships how the assumptions calculate the Reynolds numbers for maximum and
rate of carbonation of beer is affected by the beer temperature, average flowrates for each pipe diameter.
carbon dioxide pressure, and method of introduction of CO2. [7] d. Critically discuss the findings as to their relevance to the filler
b. Identify and compare three different modes of carbonation. [7] performance and beer supply system design. Suggest and justify if
c. Beer at 1°C containing 2.5 vol/vol of CO2 (at STP) is fed to a filler required any changes which would improve filling performance.
bowl and in transit it warms to 8°C. Determine the pressure the filler
bowl must be held at in order to keep the CO2 in solution. [6] All the candidates achieved better than half marks with two submissions
being very good and one being close to excellent.
Henry’s constants for CO2: In summary therefore, there were some encouraging good submissions.
Temperature Henry’s constant for CO2 Good answers need to be to the point with sufficient depth of discussion.
(°C) (kPa/mole fraction) Some submissions lacked enough critical discussion.
0 78916 However it important to ensure that the correct units are used. The unit
5 96799 of velocity is not m3/s! The critical angle of this assignment was to
10 115943 demonstrate an understanding of the effect of velocity on turbulence and
subsequent stability of fill.
1 mole of ideal gas at STP occupies 22.4 l
Molecular weights: CO2 = 44, H2O = 18 Eric Candy, July 2008

Two candidates chose this question and both passed. The first part should (b) Short answer questions
have principally been a discussion of the first order rate equation for The strongest candidate achieved 12 correct answers out of 15 with the
carbonation identifying surface area, mass transfer coefficient and weakest achieving just 4. The majority answered more than half the
concentration driving force. It could also include Henry’s law relating answers correctly.
dissolved gas concentration to gas pressure, but it was not essential for There was a good level of knowledge and understanding in the areas of
this part. turbulent flow, the parameters for calculating Reynolds Number, pumps
The second part of the question asked candidates to indentify three types and valves.
of carbonating systems (top gas, sparging, and inline venturi, for instance) Pipe friction and the expression of equivalent head loss were not well
along with some measure of comparison. understood. The unit for viscosity was not known by all but one candidate.
The final part was a relatively straightforward Henry’s law calculation
where determining the mole fraction of CO2 (0.002) was required. In (c) Long answer questions
order to complete the calculation the candidate need to perform a linear
interpolation on the Henry’s constant data in the table provide to identify
it as 108284 kPa/mole fraction at 8°C Question 1
As is always the case, the candidates are encouraged to read the a. Explain the terms austenitic, martensitic, ferritic and duplex when
question carefully and direct their answers specifically to what is being used to describe stainless steels. [8]
asked. b. Why are austenitic stainless steels used most extensively for the

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construction of beer processing and packaging plant? [4] thermal energy transfer requirement per hour by utility used. Please
c. Describe various circumstances in which the corrosion of stainless show your calculation methods in detail.
steel can take place and the precautions that can be taken to minimise c. Compare this theoretical figure with your actual thermal energy
the rate of corrosion. [8] transfer per hour (you might have to submit an estimate for this).
d. Comment as to whether and how the thermal energy efficiency
Two candidates attempted this question with the better of two poor could be improved.
answers achieving just seven marks out of twenty.
In explaining the terms austenitic, martensitic, ferritic and duplex when The candidates’ submissions produced marks ranging from poor, through
used to describe stainless steels, a good answer would have included moderate to good with one excellent result.
practical applications of each type to support specific, detailed It is important to ensure that the submission answers the assignment
information on the essential characteristics. The better of the two answers question – this was a particular problem for one candidate. Some answers
still failed to quote chemical analyses accurately. The weakest answer lacked sufficient depth of analysis and discussion.
included neither analyses nor typical applications. Good answers compared theoretical performance with actual
Both candidates provided a very superficial list of attributes for why performance along with an attempt at rationalising the difference. Again it
austenitic stainless steels are used most extensively for beer processing is vital that all working is shown as it is the approach which attracts the
and packaging plant. A reasonable answer would have listed, as a majority of the marks.
minimum, high resistance to corrosion, good weld-ability, toughness at
sub-zero temperatures and excellent ductility. Eric Candy, July 2008
Corrosion of stainless steel was covered fairly well by one candidate
with a reasonable understanding of precautions that can be taken to (b) Short answer questions
minimise the rate of corrosion. Neither answer was able to adequately The range of correct answers was between 4 and 10 which represented a
quote recognised limits for time, temperature and chloride ion disappointing level of knowledge and understanding of this area of the
concentration and preventative measures within the design and syllabus.
construction of plant. Questions about the SI unit of heat, latent heat and an example of
sensible heat were generally answered correctly by the candidates.
The majority of the remaining questions showed general weakness with
Question 2 no real pattern to the answers.
a. Describe, with the aid of a diagram, an appropriate type of Of particular concern was the apparent problem in answering the two
automatic hygienic valve for product routing from a complex bright questions on units – firstly, deriving the unit for specific heat from a given
beer operation. [8] equation and, secondly, knowing (or being able to derive) the unit of
b. Starting from an energy balance equation, derive an expression for thermal resistance.
the flowrate of a liquid through a horizontal pipe fitted with an orifice
plate, the pressure difference across the plate being measured by a (c) Long answer questions
differential manometer. [6]
c. Explain why in practice a discharge coefficient has to be applied to Question 1
the expression. [2] a. Describe the equipment used and the process of both
d. Water flows at a rate of 1.2 x 10-3 m3s-1 in a horizontal pipe of 150 i) flash (bulk) pasteurization of beer and ii) tunnel pasteurization.
mm internal diameter fitted with an orifice plate containing a Answers should include flow diagrams of typical equipment and the
concentric hole of 50 mm diameter. If the discharge coefficient is temperature profiles through the process. [14]
0.61, the density of water is 1,000 kgm-3 and the gravitational b. What problems could occur with these plants and their operation
constant is 9.81 ms-2, what will be the difference in level on a water that would compromise the integrity of the processes? [6]
manometer connected across the orifice plate? State any assumptions.
[4] Five candidates attempted this question with all candidates achieving half
marks or better with two answers being awarded the highest mark of 13.
This question was answered by three candidates with the best answer The flow diagrams of the flash pasteuriser and tunnel pasteuriser varied
achieving half marks. in quality. Worryingly there was a distinct absence of control equipment.
Surprisingly, only one candidate chose a double seat mixproof valve for The better answers included temperature and pressure instrumentation
their description of an appropriate type of automatic hygienic valve for and the (requested) temperature profiles through the process.
product routing from a complex bright beer operation. A butterfly valve Problems which could occur with these plants and their operation that
was the choice of the remaining candidates. would compromise the integrity of the processes include, for a flash
Clearly the requirement to derive an expression for the flowrate of a pasteuriser: plate leakage; low pressure in the holding tube; low
liquid through a horizontal pipe fitted with an orifice plate and temperature in the holding tube; long periods of beer recirculation; plant
subsequently carry out a calculation proved to be a daunting prospect. cleaning. For a tunnel pasteuriser: line stoppages; speed control of the bed
The derivation of the flowrate expression relied on the candidates’ leading to under or over pasteuriser; loss of water temperature control;
ability to combine Bernoulli’s energy equation (applied to an upstream plant cleaning.
point and the orifice plate), with an equation representing the same A number of candidates concentrated on the safety aspects of the tunnel
pressure difference shown on the differential manometer. An expression pasteuriser, particularly the potential for legionella bacteria, which, whilst
for velocity can then be multiplied by the orifice area to give the flowrate. very important, was not being sought as an answer on the integrity of the
No candidate satisfactorily explained that the discharge coefficient pasteurisation process itself.
accounts principally for energy losses, losses due to turbulence and eddies
and the fact that the minimum area for flow is not exactly at the orifice.
The calculation was solved by substituting the given information into Question 2
the derived expression. a. Describe insulation materials and methods for insulating vessels
and pipework that are operating both above and below ambient
Robin Cooper, July 2008 temperature, highlighting the problems that can occur if the
insulation is not applied correctly or is damaged. [12]
b. A steam pipe is to be covered with two layers of insulation. Given
the data below, calculate, as a percentage, by how much the effective
Module 3 Unit 11 – Thermal Energy Transfer for conductivity is reduced when the better insulator is on the inside.
Packaging State any assumptions made. [8]

(a) Assignment Outside diameter of steam pipe: 200 mm

a. Using a packaging line of your choice list and describe the thermal Thickness of each layer of insulation: 50 mm
energy transfer processes from Bright Beer Tank to Warehouse. Thermal conductivity of one type of insulation material: 0.16 Wm-1K-1
b. For three of these thermal processes estimate the theoretical Thermal conductivity of the other type of insulation material:

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0.04 Wm-1K-1 (b) Short answer questions

The strongest candidate achieved 13 correct answers out of 15 with the
Disappointingly, none of the candidates attempted this question. weakest achieving 9, thus this cohort had moderate to satisfactory
Candidates should understand the requirements for insulating surfaces understanding of this material.
both above and below ambient temperature. The candidates clearly had a firm understanding of basic control theory
Insulation is an example where poor heat transfer is a virtue. The vast and the basis upon which typical sensors operate. The weakest area
majority of insulation systems rely on the poor thermal conductivity of air. involved understanding open versus closed loop systems.
However to prevent convection currents causing a pathway for the heat the
air is immobilised by using a fibrous or porous structure. Above ambient (b) Long answer questions
temperature an open pore insulating material is chosen which will allow
any water vapour in the insulation to permeate out. For applications below
ambient insulation must be impervious to water, a better heat conductor, Question 1
and a closed pore structure is selected. To prevent moist air penetrating to a. Describe with the use of diagrams an operation involving a control
the cold surface and causing water condensation a material resistant to loop with which you are familiar. Your answer should include
water vapour penetration, called a vapour barrier, is applied over the appropriate labelling and identification of the various signals, inputs
insulation. Metal or plastic cladding is added to protect this barrier and the and outputs. Include an example of a particular controlling algorithm
insulation from damage. Insulation containing chloride ions should be for this system. [12]
avoided on stainless steel vessels due to the risk of corrosion, or the metal b. Discuss how the system above might be monitored from a distance
surface protected with chloride barrier paint. and how this information might be viewed or used elsewhere in the
The examiner would have expected examples of typical insulating brewery. [8]
materials for varying duties to have been included in a candidate’s answer.
The solution to the calculation would have relied on a knowledge of Three candidates chose this question and two passed. The first part should
how to apply Fourier’s equation in steady state conditions and an have included specific components of a control loop (i.e. the process, a
understanding of thermal resistance calculation for multilayer systems. A sensor, the controller, and the controlling mechanism) with a specific
candidate would, of course, have had to calculate logarithmic mean radii example of each, preferably placed in the context of a familiar control
to produce a correct answer. loop in the candidate’s working area. The candidates should have
indicated the nature of the signal that is being passed throughout the loop,
Robin Cooper, July 2008 for instance an analogue signal leaving the controller that needs to be
converted to a pneumatic signal to be used by a controlling actuator on a
control valve. None of the candidates included a controlling algorithm
describing how an error term is generated and what type of controlling
Module 3 : Unit 12 – Process / Line Control and action should be taken. The second part was weaker than the first in that
Instrumentation the candidates did not elaborate sufficiently on the difference between a
PLC controller and the SCADA system. Furthermore, the candidates
(a) Assignment spoke only in general terms that different parts of the plant could view the
a. Using a packaging line of your choice, list all the different sensors runtime/downtime data so that “plans could be made…”.
on the line, identifying their purpose, process accuracy required and
calibration check interval.
b. Obtain the manufacturer’s specification accuracy and calibration Question 2
check interval. a. Discuss the range of control systems, from the simple to the
c. Compare the manufacturers’ specification with the process complex, that may be found in a packaging plant. Present the
requirements and current calibration checks. advantages and disadvantages of each. [20]
d. Comment on any changes that should be considered.
Two candidates attempted this question and one passed. This question
It is encouraging that there were some good submissions which identified asked candidates to examine the range of control systems from simple to
all the sensors on the chosen packaging line. It is important to rationalise complex. The examiner did not intend the candidate to describe all the
the process requirement with the specified acceptable maximum tolerance various items that must be controlled, nor a detailed explanation of a
for the parameter measured. For example, is +/- 1°C acceptable for a single control system. The focus should have been discussing the range of
temperature sensor controlling a pasteuriser? The effect of this variation controlling systems from the simple (for example, time stamp printing in
on the process it is monitoring or controlling. response to a proximity detector switch) to the complex (for example,
More detailed analysis of performance and calibration records would beer pasteurizer control relying on multiloop control using P, I, and D
have been preferable with some submissions. controlling algorithms). Stronger answers should have included specific
The better submissions entered into the spirit of the assignment by details in how and why a control system was executed and why it was
critically investigating the chosen quality system and identifying where simple or complex. None of the candidates described the advantages and
improvements could be made along with suggesting possible solutions. disadvantages of the systems they chose to describe.

Eric Candy, July 2008 Tom Shellhammer, July 2008

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MASTER BREWER EXAMINATION 2008 at his disposal to ensure that modification proceeds satisfactorily to pro-
duce a malt to the required specification?
Module 1 – Raw Materials and Wort Productuion This question was attempted by only 6 (18%) candidates, with 4 (67%)
achieving a pass mark. There were several good answers to this question
from candidates who had given some thought to this topical issue. The
There were 34 papers were returned; this is twice last year’s number. 21
question invited speculation but in general brewers seem unwilling to
(62%) candidates achieved a pass mark. This success rate should be com-
move outside their comfort zone and think through the possible conse-
pared with previous years’ results, as shown in the chart below.
quences of climate change. For instance, many stated that global warming
will produce drier weather, this may be true of some parts of the world but
for other parts wetter climates may well be the future. Only one candidate
pointed out that if the world warms up then the latitudinal zone for grow-
ing barley may shift northwards in the northern hemisphere or southwards
in the southern hemisphere. The second part of the question elicited some
sound advice to maltsters for ensuring indifferent quality barley produces
satisfactory quality malt.

Question 3 – Hop Markets

Discuss and explain the recent turbulence in world hop markets.
Describe some techniques that may be used to lessen the effects that
these events have brought about.

This question was attempted by 21 (62%) candidates with 17 (81%)

This year the general standard of papers was not particularly good but
achieving a pass mark. Clearly, candidates have been studying previous
there were several papers with marks above 60%, which is unusual. The
years’ exam papers and have seen this question, or one similar, comes up
pass rate at 62% compares unfavourably with most other years.
quite often. I was pleasantly surprised to see haw many candidates had
I make no apologies for reminding candidates and mentors again to
studied the current industry press (and possibly the internet) and identified
take note of the following points:
the ‘turbulence’ as being (amongst other reasons) crop failures due to
• Candidates often fail to answer five questions or answer their fifth ques-
adverse weather conditions, loss of growing acreage, the use of hops for
purposes other than brewing and a devastating warehouse fire in the USA.
tion very badly. Good time management is as important in the examina-
Techniques for lessening the effects of a hop shortage were described rea-
• Too many candidates fail to read the questions carefully enough and
tion room as it is at work.
sonable well by most who attempted this question.
either miss out some parts or misinterpret the question. For example one
candidate answered the question about mash conversion systems by
Question 4 – Removing Unwanted Ions in Brewing Water
• Mentors should be encouraging their pupils to get as wide a range of
describing mash separation systems.
Outline two different methods of removing unwanted ions from a raw
water supply and describe, with advantages and disadvantages, typi-
practical brewing experience as is feasible in their individual situations
cal commercial installations which utilise these methods. List which
and to read as widely as possible from textbooks, journals as well as elec-
ions are important to the brewing process and explain the contribu-
tronic media. Mentors also have a responsibility to ensure that candidates
tion each one makes to final beer quality; rank them in order of their
under their tutelage are properly prepared for the examinations.
importance to the process and indicate how you have determined the
ranking order.
Question 1 – Maltings Audit
This question was attempted by 24 (71%) candidates but only 9 (38%)
Describe an audit to assess the suitability of a maltings to provide
achieved a pass mark. The general standard of answer to this question was
malt for brewing. Discuss how such an audit process can ensure that
very poor with a surprising number of candidates unable to describe cor-
the malt conforms to the brewer's specification as well as providing
rectly either a de-ionisation plant or a reverse osmosis plant. Those candi-
assurances for food safety.
dates who made a reasonable attempt were unable to supply anything like
the amount of detail which a good answer requires. Many candidates
This question was attempted by 12 (35%) candidates with only 5 (42%)
could not define the terms temporary hardness and permanent hardness
achieving a pass. Few brewing companies now own their own maltings so
properly. This aspect of water composition is key to brewhouse perform-
it becoming increasingly difficult for brewers to get experience in the
ance and control of pH.
malting industry, though mentors must try and get their pupils placements
in maltings, whenever possible. Audits are the best way for a brewer to
ensure that the malt purchased will conform to specification. A good
Question 5 – Physical and Chemical Changes during Mashing
answer to this question would have briefly outlined the malting process,
Discuss how the brewer can influence the chemical and physical
but not made this aspect the core part of the answer. Other issues which
changes which occur during the mash conversion process. Describe
• quality management systems, e.g. quality policy, organisational struc-
could have been discussed would include:
two systems for carrying out this process indicating how these meth-
ods evolved and the parameters which must be controlled in order to
ture, management commitment and review, internal audit, record keep-
guarantee the quality of the wort produced.
• maltings environmental standards, e.g. buildings, equipment, mainte-
ing, traceability etc
This question was attempted by 29 (85%) candidates with 12 (41%)
• product control, e.g. malt inspection and analysis, stock rotation control
nance housekeeping and hygiene, etc
achieving a pass mark. Despite this being the most popular question, the
general standard of answers was poor. Many candidates failed to explain
• personnel, e.g. training and protective clothing.
on non-conforming product
how and why different mashing systems evolved and these historical
aspects are important in illuminating and explaining the different ways of
brewing beer. Surprisingly, the parameters which must be controlled in
order to guarantee the quality of wort produced were only adequately
Question 2 – Global Warming and Barley Growing described in the best answers.
What might be the effect of rising global temperatures on farmers'
ability to produce barley suitable for malting? Is it possible that climate
change is influencing the current state of the global market for malting- Question 6 – Wort Boiling Systems
quality barley? There have been several innovations in the technology of wort boiling
systems over recent years. Describe the operation of three commer-
When the quality of barley is poor, what techniques does the maltster have cially available systems, indicating how each one achieves the physical

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and chemical changes which wort should undergo during the boiling labus by many candidates. In particular it was surprising that there were
process. Explain the market forces that are driving these develop- only 13 attempts at the filtration question whilst the more general health
ments. and safety question was the most popular with 23 answers returned.
Examination technique can still be improved. In some instances candi-
This question was attempted by 23 (68%) candidates and 11 (48%) gained dates answered a different question to the one set (Question 2 was explic-
a pass mark. Candidates were much better prepared for this question than itly about health and safety not food safety). Others wasted time repeating
several years ago when a similar question was asked. With one surprising information already presented earlier in the answer (again Question 2
exception, all the systems on offer from the major manufacturers were where in some instances candidates described slips, trips and falls three
described. Many candidates failed to highlight the two crucial purposes of times in the same answer and with the same information, under separate
boiling which are the chemical processes that take place at high tempera- headings fermentation, processing and bright beer).
ture and the physical process of removing volatiles by evaporation. A Candidates need only write the question number at the start of their
good answer described how each of the systems chosen satisfied these two answers. There is no benefit or score attracted by copying out the question
requirements. from the examination paper.
There were several candidates who failed to note that the question
asked: ‘innovations ... over recent years’ and ‘commercially available sys-
tems’, and then went on to describe direct fired coppers. Few candidates Question 1
failed to observe that the rapidly rising cost of energy is one of the drivers What measures should be taken in fermentation and beer processing
behind these new technologies. to ensure colloidal haze stability in bottled or canned beer with a
declared shelf life of twelve months? What tests are available to
determine the level of stability achieved?
Question 7 – The Importance of pH
Discuss the importance of pH during the wort production process and 15 candidates attempted this question with only 4 passing (27%).
its influence on subsequent processing and beer quality. Provide typi- The first part of the question worth 15 (75%) of the marks required a
cal values at each stage. Review the different methods that have been description of colloidal haze stability and a proposed scheme to achieve a

• General factors to ensure good fermentation. For example yeast viabili-

used to adjust pH levels in the brewhouse and which conform to twelve month shelf life in bottle or can. Conditions to consider included:
national or international regulations.
ty, wort dissolved oxygen, temperatures, yeast cropping, yeast storage

• Maturation. Time and temperature. Oxygen control.

This question was attempted by 22 (65%) candidates with 15 (68%) etc.

• Filtration. Use of precoats & body feeds. Temperatures.

obtaining a pass mark. Although the pass rate was high there were very

• Stabilisation treatments. Proposed treatments (for example silica hydro-

few good answers. Calcium was identified by most as having a significant
effect on pH in both the mash conversion stage as well as the boiling stage
though there were quite a few who failed to explain the mechanisms. Few gel, polyvinylpolypyrrolidone), methods of application and suggested
candidates described adequately the various methods, which include rates of use.
adding naturally produced lactic acid as well as mineral acids such as
phosphoric and sulphuric, depending on local legislation, for reducing pH The second part of the question worth 5 (25%) of the marks invited a brief
either in the mash conversion vessel or copper. description of the various tests that can be used to measure haze stability.
For example an as is test would be to measure the haze of a sample stored
at room temperature after twelve months. More useful are the various pre-
Question 8 – Brewhouse Health and Safety Audit dictive tests such as the heat forcing or Chapon tests.
Design an audit to check on health and safety provisions for operators Most answers scored poorly because they failed to make a practical
in a brewhouse and illustrate your answer with pertinent examples. proposal of a stabilization procedure to achieve the required shelf-life and
Discuss how such an audit would ensure that risk and hazard are cor- merely suggested a few of the treatments that are available for beer stabi-
rectly identified and how these factors must be evaluated in order to lization.
recommend changes which would improve safety.

This question was attempted by 27 (79%) candidates with 19 (70%) gain- Question 2
ing a pass mark. Similar questions have been posed in previous years' Describe the main health and safety hazards that may be present in
examinations and I have advised candidates, in previous exam reports, to the fermentation, processing and bright beer areas of a typical brew-
outline a structured procedure for checking all the activities that ensure ery. What steps can be taken to minimise the risks to personnel work-
health and safety of operators. These can typically include evaluating risk ing in these areas?
and hazard, standard operating procedures, training initiatives and much
else, all backed up by suitable records. Where appropriate, pertinent 23 candidates attempted this question with19 passing (83%). Most were
examples help illuminate a good answer. Candidates should be aware that comfortable passes and there was one very good one.
the term ‘health and safety’ relates to the health and safety of brewery per- This was a single part question worth 20 (100%) of the marks.
sonnel, whereas the term ‘food safety’ relates to the health of the final con- A table would have been an effective way of approaching this question
sumer. using headings for the hazard itself, the nature of the hazard, and steps that
can be taken to minimize the risk. It was expected that a discussion of the

• Carbon dioxide
Bob Illingworth July 2008 main hazards would have included:

• Hot water & steam

• Detergents and sterilents
• Electricity
• Confined spaces
Module 2 - Fermentation and Beer Processing

• Manual handling
• Kieselguhr
Scripts for marking were received from 24 candidates and 15 gained pass

• Slips, trips and falls

grades, a pass rate of 62.5%, which is a deterioration compared to last

• Moving equipment
year and there were no passes at Grades A or B. There were 5 passes at
grade C and 10 papers at grade D. Of the candidates who did not pass
there were 7 papers at grade E and 2 at grade F.
As in previous years, the range of questions set were best answered Actions to minimise the risk should have included a description of activi-
using a combination of tables of data, labelled drawings or flow diagrams, ties such as safe chemical storage, ventilation of fermentation cellars, stor-
and/or text laid out in the form of bullet points. This approach is usually a age and handling methods to minimize exposure to kieselguhr dust, man-
more effective way of presenting the information required than many ual handling, housekeeping, use of personal protective equipment etc. It
paragraphs of long hand. was also expected that answers would include mention of management
As a generalisation the poorer scoring this year appeared to be due controls such as COSHH, risk assessments, work permits, hazard report-
quite simply to a lack of a comprehensive technical knowledge of the syl- ing etc.

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The best answers systematically covered all of the areas mentioned have started with an assumption regarding the current recipe (for example
above. Less complete accounts often identified the hazards correctly, but 100% malt) and then proposed a certain adjunct rate for the modified
then only made vague statements regarding the steps that should be taken. recipe (for example 15% of a nominated liquid or cereal adjunct).
For example when handling detergents, “Wear PPE”, needed also to men- A suitable trial programme would then have been described in terms of
tion the actual equipment such as goggles, visors, gloves, aprons etc. the number of trials and perhaps proposing a start up at pilot scale before
Some answers included discussion of food safety which was not within progressing to industrial size brews. Factors to evaluate should have

• Wort composition (with regard to factors effect yeast performance)

the scope of the question. included:

• Fermentation performance over successive yeast generations

• Beer filterability
• End product analyses including haze stability
Question 3

• Sensory including expert panel, the nature of the test used, the number
Starting at the laboratory stage, describe a yeast propagation process
appropriate to achieve sufficient yeast to pitch 1000 hl of lager or ale
wort. of trial samples, and perhaps the use of external consumer tests.
Outline routine procedures used to ensure a consistent supply of high
quality pitching yeast for all fermentations. The second part was worth 4 (20% of the marks). All that was required
were some brief notes on the likely composition of the project team
19 candidates attempted this question with 16 passing (83%). Most were including not only brewers but also engineers, planners, packagers, quali-
comfortable passes and there were three very good answers. ty and brand owners.
This was a two part question. The first part attracting 14 (70%) of the To answer this type of question well candidates need to have a clearer
marks invited candidates to describe a yeast propagation process usually idea of what constitutes a trial programme. For a brand of strategic impor-
starting with a laboratory slope and finishing with sufficient volume/cell tance it is not usually adequate to undertake an immediate changeover to
count to pitch 1000 hl of wort. Conditions to discuss included the new recipe, even if a blending programme is included.

•
•
Type of media or wort specifications

•
The need for sterility, types of vessel and sizes Question 6

•
Volumes and top up volumes and ratios, Discuss the possible causes and effects of microbiological contami-
Temperatures, times, use of stirring or aeration, yeast cell count, wort nation of beer in the fermentation and beer processing areas of a
gravity etc. brewery.
Outline the steps for taking an aseptic sample from a tank of beer.
The second part of the question worth 6 (30%) of the marks was more Briefly describe the microbiological techniques used for detection of
general. Areas to discuss were about conditions of yeast storage and han- beer contamination.
dling, such as temperature and time, sterilization of storage tanks, mains
and air mains, together with typical tests used to determine the routine 12 candidates attempted this question with 7 passing (58%). There was
quality of pitching yeast. one good answer.
The best answers used full page flow diagrams or tables to demonstrate This was a three part question.
the process through laboratory and industrial propagation to first genera- The first part was worth 12 (60%) of the marks.

• Plant design leading to inadequate cleaning e.g. Pipework deadlegs,

tion brew. The second part of the question was also comprehensively cov- The causes of microbiological contamination may include:
ered by describing conditions of yeast storage, yeast generations, cleaning

• Inadequate cleaning & sterilizing of tanks, hoses, fittings, gas mains

and sterilizing, acid washing and microbiological analyses. Weaker shadows under cooling pipework, poor surface finishes (crevices)

• Perished valve or door rubbers

answers were usually characterized by a lack of detail and unrealistic dilu-

• Poor environmental housekeeping

tions during scaling up.

• Use of contaminated yeast for pitching

• Poor fermentation performance
• Overfoaming
Question 4

• Beer recovery
Describe the range of equipment available for the filtration of green

• Inadequate procedures of lack of training on hygiene related procedures

beer. Discuss the advantages and disadvantages of each.

13 candidates attempted this question with only 5 passing (38%). There

• Haze
were no good answers. Effects of microbiological contamination in beer are often observed as:

• Ropiness
This was a single part question worth 20 (100%) of the marks.

• Deposits
This should have been a very straight forward question. It was expected

• Super-attenuation
that candidates would base their answer on a description of plate and

• Off-flavours
frame, candle, leaf and crossflow filters. A well labelled diagram of each
would have been a good starting point to achieve this. Supporting text
should have gone on to discuss the relative advantages and disadvantages
of each. Parameters to consider were those such as flow rate, turnaround The second and third parts of the question were each worth 4 (20%) of the
time, ease of automation, maintenance requirements, cleaning, flexibility marks.
etc. The second part required a back to basics description for taking an
The main reason candidates scored poorly was due to a lack of detailed asceptic sample. This section was generally competently covered.
knowledge of the equipment. In particular candidates tended to make only The third part required a description of typical media together with
vague statements regarding the advantages and disadvantages. innoculation techniques, such as spread plates, pour plates, forcings etc.
Incubation times and temperatures should also have been included. For
most candidates this was the weakest part of their answer.
Question 5
Due to malt shortages and increasing prices a brewer is considering
reducing a proportion of the malt in a premium lager, ale or stout Question 7
brand with a liquid or cereal adjunct. Describe a suitable trial process Describe Key Performance Indicators (KPIs) that could be used to
for evaluating the effects of the change in fermentation, beer process- monitor the performance of the fermentation and beer processing
ing and finished product and for achieving a flavour match with the areas of a brewery. For each KPI indicate the factors that influence
original liquid. Discuss the likely composition of the project team. performance and the areas to focus upon in order to achieve further
improvement.
Nine candidates attempted this question with seven passing (78%). There
was one good answer. 18 candidates attempted this question with 7 passing (39%).
This was a two part question. This was a single part question worth 20 (100%) of the marks. There
The first part was worth 16 (80%) of the marks. A good answer would were two good answers.

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This question was intended to assess candidates’ knowledge of the factors 50, 000 hectolitres of 250 ml cans
that determine the operational and business effectiveness of the fermenta- 350, 000 hectolitres of 330 ml cans
tion and beer processing areas of a brewery, and how these can be meas- 600, 000 hectolitres of 500 ml cans.
ured and improved upon. The line should have the capability of packing into both solid board
An ideal answer would have presented the information in the form of a multi-pack and tray and shrink formats.
table with separate columns naming and describing each key performance Draw a diagram showing the layout of the line.
indicator (KPI), indicating typical performance and suggesting relevant State any assumptions made, including the expected staffing levels,
areas to focus on to achieved improved performance. Typical KPIs that and justify the choice of equipment and machine throughputs.
might have been mentioned ranged from conformance to process time,
losses, quality indices, utilities usage, productivity and financial meas- This was the second most popular question with 22 (85%) of candidates
ures. answering. However, it was generally poorly answered with only10
Few candidates got near the full scope of the question. Many men- (45%) reaching the pass standard, though there was one extremely good
tioned various in process targets such as original gravity, attenuation limit answer.
or yeast viability. Although important, such factors are not normally con- Line design was dealt with disappointingly by candidates this year.
sidered to be KPIs. Please note, where local abbreviations are used it is Many candidates could not deal with the three different sized cans, nor
essential that these are adequately defined. could they identify clearly unfeasible options when calculations went
wrong. Good answers could clearly identify the required plant and justify
selections. The calculation based on sensible assumptions of operating
Question 8 time and machine efficiencies formed a good core of the marks.
Review the techniques available for the recovery of beer from yeast
and describe the advantages and disadvantages of each. What are the
options available for the further utilization or disposal of the recov- Question 2 – Management Information System
ered beer? Describe the key features of a computer-based management infor-
mation system used to facilitate the control of all aspects of packag-
11 candidates attempted this question with seven passing (64%). There ing production from order planning to dispatch.
were no particularly good answers. Your answer should include reference to supply chain, production
This was a two part question. and quality data handling.
The first part was worth 15 (75%) of the marks. This section should
have described the design and operation of equipment most commonly in This was the least popular question with only six (23%) candidates
use for recovery of beer from yeast, typically yeast presses, centrifuges answering. It was generally poorly answered by those attempting and
and cross flow filters. Advantages and disadvantages are generally only two (33%) achieved the pass mark, though one of these did answer
around yield, rate of processing, cleaning and maintenance, automation particularly well.
potential and space requirements. There was the potential in this question to display a broad knowledge
The second part of the question was worth 5 (25%) of the marks. When of the information needed to run a packaging line and the benefits of

• Whirlpool or before wort cooler

recovered beer is added back to the process the possibilities include: organising that information. Good answers mentioned a wide range of

• Fermentation vessel during active phase of fermentation

data and explained the benefits of a variety of reports for control of the

• Beer transfer main between fermentation and cold ageing

operation. Poorer answers only contained a very restricted range of infor-

• Beer transfer main before filtration (from cross flow filter)

mation with little thought as to the uses of the data.

Typical addition rates of recovered beer range between 0-15%.

Question 3 – Environmental Impact
John Shardlow - July 2008 What is the environmental impact of a returnable bottling line opera-
tion?
How can this impact be measured and minimised?

This was a moderately popular question with 20 (77%) of candidates

Module 3 – Packaging and Beer Dispense answering. It was well answered with 13 (65%) achieving the pass stan-
dard, including one excellent answer.
In 2008, 26 papers were received of which 15 (58%) achieved the pass A good answer to this question included a broad view of the various
standard. This represents a slight increase on last year’s percentage. direct and indirect impacts on the environment which are caused by the
Pass marks were seen at grades B, C and D. operation of a packaging plant. Energy usage, material usage and emis-
The increase in pass rate back to the level of 2006 was encouraging and sions (including noise) of both the plant and indirectly the supply chain
the overall standard was also improved on last year. There were three par- could be included. Poorer answers had limited scope (e.g. focussing sole-
ticularly good scripts and several candidates produced excellent answers ly on the bottle washer) and did not deal convincingly with the control of
to some of the questions. the discussed impacts.
It is worth noting that again five of the questions were more popular
than the other three, though not as markedly so as last year This suggests
a clear focus by candidates in a restricted part of the syllabus. The paper Question 4 – Budgets
is taken from the full scope of the syllabus and candidates who are con- Describe the components which make up a revenue budget for a keg
versant with the full breadth will have an increased chance of scoring OR cask filling line.
highly. What would be the impact of a significant energy cost increase on the
The best candidates were able to clearly demonstrate their knowledge various components described?
and direct experience of a topic area. To score a good pass this standard is What steps could be taken to reduce the effect of the increase? Both
needed across a range of answers. revenue and capital expenditure options should be considered
Generally, examination technique was good with only a couple of can-
didates appearing to run out of time through poor planning this year. It is This was the third least popular question with only ten (38%) of the candi-
almost always the case that five evenly spread answers will achieve a bet- dates answering of whom six (60%) achieved a pass.
ter overall result than all the effort being focused in two or three answers. Good answers to this question gave a clear outline of a revenue budget
Lack of detail in scripts, typified by answers containing only sweeping and the relative importance of the main contributors to spend. The energy
generalities, lead to very few marks being scored. part of the question requires a knowledge of the importance of the energy
contribution to all components not just the energy used directly in the
plant and good answers were able to identify this and this lead to sensible
Question 1 – Plant Design cost saving measures. Poorer answers had an unstructured approach with
Design a canning line to produce the following annual volumes based little feel for the relative magnitudes of the various budget components
on 24 hr production availability and a 7 day week and therefore cost saving measures were general and untargeted.

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Question 5 – Retail Outlet Module 4 – Materials and Wort Production

What are the important features in a retail outlet cellar, or equivalent
beer storage area, selling both draught and small pack beer? Summary
Explain how the features described help to assure the best quality Of the 14 candidates this year 12 passed (85.7%), a higher proportion than
taste, presentation and hygiene of the retailed product. last year but with lower overall marks. Only one candidate achieved a B
grade, five a C grade and six a D grade. Knowledge and experience of
This was the most popular question with 24 (92%) of candidates answer- brewing central services was good and the results for Health and Safety
ing. It was also well answered with 16 (67%) reaching the pass standard. were excellent. The Finance question was again avoided and where
The key to a good answer in this question was to relate the well known attempted was failed. That was disappointing as finance is so important
features of a cellar to the quality assurance part of the question. Poorer for brewers to understand and the questions are generally not difficult. It
answers were restricted to describing the features of a cellar with no was encouraging to see very few examples of questions being interpreted
explanation of why the features are important. Good answers were able to to fit the candidate’s knowledge.
relate the features to specific quality parameters and detail the conse-
quences of poor cellar design.
Question 1 – Refrigeration
Attempted by 10, passed by 7 - (70%)
Question 6 – Keg/Cask Control of Cleaning and Filling For a brewery with a centralised refrigeration system show on a dia-
Describe in detail, the processes of internal cleaning and filling of kegs gram the main components with typical refrigerants, temperatures
OR casks. and pressures.
Explain how the processes ensure that product quality is not compro- How can efficiency be assessed for the overall system and describe
mised. how the critical items of plant affect efficient running.
What process and quality control checks are made to ensure correct If performance was declining what could be the possible causes and
operation of the plant involved? how could the problems be rectified.

This was a moderately popular question with 19 (73%) of candidates Answers showed the many types of systems in use in the candidates’
answering. It was generally well answered with 13 (68%) achieving the experience. There were some good detailed diagrams but several were
pass standard, including two excellent answers. sketchy with few details. All candidates understood the principle of per-
To achieve the best marks in this question the technical detail of clean- formance measurement and most had a good understanding of investigat-
ing and filling was first required. Some detail of why the processes are in ing and rectifying a drop off in performance.
place and the consequences of process failure would then lead logically to
checks to put in place to confirm correct operation. Again practical detail
is needed to produce a substantial answer. Poorer answers to this question
tended to restrict the discussion exclusively to the process of cleaning and Question 2 – Process Gases
filling only and ignored the other parts of the question. Attempted by 13, Passed by 12 – (92%)
Describe, with a labelled diagram, the principal uses of process gases
within a brewery including a small pack and a large pack operation.
Question 7 – Packaging Materials How can gas quality be ensured and what procedures can be put in
For a bottling line handling non-returnable bottles, packed into both place to eliminate process gasses as a product quality complaint.
tray and shrink and solid board multipacks, describe how poor pack- What factors determine whether it is economical to recover CO2 from
ing material quality can adversely affect each stage of the process brewing and packaging.
from material intake to finished goods warehouse.
Discuss suitable specifications for packaging materials. Generally well described with a wide interpretation including sterile air
Describe the systems required to ensure that these specifications are alongside the more obvious CO2 and Nitrogen. Ensuring gases were not a
met. feature of potential customer complaints was less well answered but the
better candidates emphasised the importance of routine checks. There was
This was the second least popular question with only eight (31%) candi- a good understanding of factors that would make CO2 recovery viable.
dates answering. It was only moderately answered with four (50%)
achieving the standard needed for a pass.
To score well on this question evidence of understanding of the impact Question 3 – Quality Systems
of material quality at a practical level needed to be demonstrated. By dis- Attempted by 12, Passed by 8 – (67%)
cussing the specifications a comprehension of the important parameters There have been a number of complaints about an off flavour in a
could be demonstrated and finally some detail of methods of quality brewery’s packaged beer. Describe in detail:
assurance was needed. Poor answers tended to focus only on one part of a) A short-term action plan to contain the problem;
the operation or only deal with one or two materials (e.g. only the bottle b) A systematic investigation to identify source of the problem.
itself). Note that the problem does not appear at the time of packaging but is
recognisable within one week of packaging.

Question 8 – Bottling/Canning Process Control A straightforward question that was well answered although several can-
For either a bottling or a canning operation, list the process control didates did not emphasise the importance of the urgency to contain a prob-
measurements which should be taken to assure product quality. lem in the short term. The better answers included a very detailed descrip-
Explain the rationale for each measurement, and detail the expected tion of procedures to investigate, drawing in all the relevant personnel as a
targets and tolerances. team. Some described methodical problem solving techniques and the
What actions should be taken if an out-of-tolerance result is importance of records and traceability.
recorded?

This was the third most popular question with 21 (81%) of candidates Question 4 – Project Management
answering. It was well answered with 16 (76%) achieving the pass stan- Attempted by 9, passed by 6 – (67%)
dard and there were two excellent responses. What factors would be considered in the justification for the following
The marks in this question were evenly distributed between the three projects?
parts. Poorer answers either lacked breadth (only focusing on the filler) or a) High efficiency motors for a packaging line.
depth (not being able to supply necessary detail). Good answers focused b) A new boiler.
on product quality, identified critical areas where quality could be com- c) Additional fermenting vessels.
promised and gave sensible specifications and corrective actions. To integrate a new multi-packing box erector into a bottling line,
describe methods and procedures to ensure transfer of ownership
Jon Brown – July 2008 from the project team to the packaging department.

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Candidates were good at identifying justification for project expenditure last question at the end of the paper and for others there was no under-
and some had clearly experienced an implementation. The better answers standing of the difference between fixed and variable costs.
stressed the importance of early involvement of user department person-
nel to build in transfer of ownership. The less good candidates relied on Ian Bearpark - July 2008
procedures to control contractor performance.

Module Five - Case study

Question 5 Air Compressors
Attempted by 8, Passed by 6 – (75%) This year 20 candidates sat the paper and 13 passed (65%),which is a
Describe, using diagrams, two types of air compressor and the advan- slight improvement on last year (58%). 9 candidates chose question 1 and
tages and disadvantages of each for brewery operation. six of those achieved a pass, 11 candidates chose question 2 and seven of
How can costs for compressed air generation and distribution be min- them achieved a pass.
imised? It was again apparent that some of the marginal and failed candidates
did not read the questions carefully, particularly question two which was
Less well understood than refrigeration but again demonstrating the diver- about management systems not just quality systems however it was good
sity of equipment in use. Some good diagrams but others had no real expe- to note more scripts being planned for layout and structure with some bet-
rience. Most candidates demonstrated knowledge of potential losses from ter use of tables and diagrams.
leaks but few considered efficiency at generation or management of multi-
ple compressors. Question 1
Stating your assumptions, describe in detail:
a) The recipe and
Question 6 – Plant Capacity b) The product costing
Attempted by 5, Passed by 2 – (40%) For a 5% ABV canned lager to be sold in a take home market of your
For a brewery producing two types of beer, 50,000 hl annually at 9% choice.
ABV and 350,000 hl annually at 5% ABV, estimate the size and num- What key areas of planning, procurement, production, warehousing
ber of fermenting, conditioning and bright beer tanks required to run and transport will significantly influence the quality and profitability
the plant on a two shift pattern for five days/week (80) hours. State of this product?
any assumptions made and specify any raw materials used. Assume:
a) the brew length at 5% is 500 hectolitres and all output is bottled at The question was looking for an understanding of standard product cost-
150 hl/hr; ing and a good way to start the answer was with a component cost table or
b) time from mashing to filtered bright beer is 3 weeks for the 5% matrix for the unit of sale chosen such as a case of 4x6x500ml. Each part
and 4 weeks for the 9% beer; of the costing should then be derived from recipe calculations and materi-
c) peak weeks are met without overtime but all brewing time is used. al bills also making reference to the overhead costs, their level and split.
If demand for the 9% beer increases to 60,000 hl annually and Good candidates then commented on the merits of marginal costing to
390,000 hl annually for the 5% beer, what plant or operational modi- show understanding of the relationship between fixed and variable costs
fications would be necessary. Identify where costs would change. as well as describing manufacturing techniques which could reduce unit
costs if pursued.
This question was not attempted by many and poorly answered. Some Candidates covered raw materials in brewing quite well but packaging
candidates derived the number of vessels logically but assumptions and materials and processes were not so well covered with few candidates
descriptions lacked detail. The effect of changes in capacity on costs also highlighting the proportion of final pack costs associated with packaging
lacked detail but did include some good ideas on maximising outputs cans and very little mention was made of basic packaging performance
without additional plant. measures such as fill control. Good answers referred to extending and use
of high gravity brewing, the importance of loss monitoring and control at
every stage of operations and the impact of efficiency on items such as
Question 7 – Health & Safety utilities. Also the good candidates linked this with the planning process to
Attempted by 10, Passed by 10 – (100%) ensure stocks were at the right level and process flow was optimized.
For a packaging line describe the potential hazards for each item of Overall there was still far too much emphasis upstream of the bright
equipment, service or area. beer tank with significantly less understanding illustrated for processes
Describe the safety procedures that should be in place for the follow- and controls down stream.
ing individuals to carry out work on the line: Some candidates then spent too much of their time going in to the detail
a) Production operator; of product quality system and analytical specifications without making the
b) Maintenance technician; link between quality, cost and profitability this meant they spent little or
c) Contract staff from the equipment supplier. no time considering planning, procurement, transport and warehousing
restricting their opportunity to gain marks. The better candidates managed
This question was very well answered and should re-assure us all that can- their time to ensure they described some key points in these areas.
didates have a firm grip on the importance of Health and Safety. There
was a clear understanding of the hazards associated with a packaging line
and how different personnel are affected. One candidate achieved full Question 2
marks for this question. In a new brewery operation based in an emerging market, what man-
agement systems would need to be put in place to ensure beer quality
and legal compliance?
Question 8 – Finance Describe how these systems would be prioritized, implemented and
Attempted by 3, Passed by none – (0%) maintained.
If electricity, gas (or oil or coal), water and effluent are considered as
semi-variable costs, provide a chart identifying for a brewery with This question is looking for the candidate to exhibit knowledge of how
both bottling and kegging, the areas of consumption and the propor- management systems are structured and tie together, too many candidates
tion of typical costs. For each area specify what proportion could be launched in to it without reading what it asked and went on to focus totally
considered as variable and why. on quality systems only thus severely restricting the amount of marks
Describe the equipment and control processes that need to be in place available to them.
to monitor and control the departmental financial performance for In the introduction candidates should describe the scope of the brewery,
electricity, gas (or oil or coal), water and effluent in a manner that its size, site and local environment; from this a management structure is
permits end user accountability. defined along with the relevant workforce structure and skills require-
ment.
Once again candidates avoided this question on finance and although Good candidates then outlined quality systems such as ISO, and
straightforward, all scored less than the pass mark. For some it was the HACCP describing how they can be used as a management tool rather

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than their definition. Linked to quality systems good answers covered systems described and comment on priorities, people requirements, out-
health and safety systems such as COSHH and Human Resource schemes line costs and the order in which they could be set up. Good candidates
including grading and training. illustrated how these systems would be built from the ground up by sound
Legal compliance called for the candidate to introduce local expecta- management rather than the easier option of imposing a large company
tion in the assumption and cover both business requirements such as envi- system from afar.
ronmental and taxation such as excise duty. Most candidates mentioned auditing as a key part of system mainte-
Only a few of the better candidates referred to the requirements of nance and this along with specification management, taste evaluation and
packaging particularly primary package material checking and content record keeping was well covered by many.
control including provision of insurance for third party injury or product
contamination.
The second part of the question required the candidate to integrate the Jim Robertson - July 2008

THE GENERAL CERTIFICATE IN BREWING for a ‘pass’ to be awarded: ‘credit’ is set at 48 correct answers, and ‘dis-
AND PACKAGING EXAMINATIONS tinction’ is set at 54

Colin McCrorie
November 2007
The Autumn series of examinations for the General Certificates in
Brewing and Packaging (GCB, GCP) was held on 12 November 2007 at
May 2008
35 centres in 15 countries.
The Spring series of examinations for the General Certificates in Brewing
This was the fifth of the new multiple-choice examinations with spe-
and Packaging (GCB, GCP) was held on 12 May 2008 at 42 centres in 16
cialist options for brewing and packaging variations, i.e. Cask, Keg, RB
countries.
(Returnable Bottles), NRB (Non Returnable Bottles) and Can.
This was the sixth of the new multiple-choice examinations with spe-
There were 286 entries, with an overall pass rate of 57%, slightly lower
cialist options for brewing and packaging variations, i.e. C&F, Cask, Keg,
than of late.
RB (Returnable Bottles), NRB (Non Returnable Bottles) and Can.
The break-down between GCB and GCP results is shown below in
There were 227 entries, with an overall pass rate of 63%, better than the
table 1.
57% achieved at the previous November examination.
Table 1 The break-down between GCB and GCP results is shown below.
Subject Distinction Credit Pass Fail Pass rate % Table 1
Brewing 0 18 57 73 51 May 2008
Packaging 0 20 68 50 64 Exam Option Distinction Credit Pass Fail Total
GCP Can (Packaging) 1 2 1 4
Keg (Packaging) 8 7 15
NRB (Packaging) 5 4 9
RB (Packaging) 9 18 27
GCB C&F (Brewing) 5 36 69 52 162
Cask (Brewing) 1 8 1 10

Diagram 1: a graphical distribution of pass grade by option.

Comments
Overall the pass rate for GCB was, unfortunately, one of the lowest on
record, with ‘C&F’ significantly worse than ‘Cask’.
For GCP, however, the figure was to expectation (around 67%). Diagram 1: a graphical distribution of pass grade by option
No distinctions (90%) were awarded.
The difference in performance between GCB and GCP candidates is Comments
difficult to explain, especially given that 30 of the 60 questions set for all Overall the pass rate for GCB was 69%, with 5 distinctions (90%) and 37
six papers come from a common question bank, being based on the same credits (80%): this was a significant improvement in standard, especially
sections of the syllabi, i.e. beer quality, plant cleaning, engineering main- in the number of ‘good’ passes.
tenance and utilities. For GCP, however, the figure was, at 45%, disappointingly low, with
One question from the GCB paper was deleted from the marking one distinction and no credits being awarded.
schedule as it contained a significant spelling error. It appears from the results that many of the candidates who achieved
It appears from the results that, unfortunately, many of the GCB candi- marks around the pass/fail interface have been ill-prepared for this
dates have been ill-prepared for this examination. examination: there was evidence within these scripts of candidates with
Companies are encouraged to ensure that the support and commitment extensive knowledge of one syllabus section and little if any knowledge of
they give to their examination candidates i.e. the quality of course materi- other sections, suggesting they went in to the examination armed only
al, tutoring and mentoring, is always to the required standard. with experience of their own job, with no additional preparation or study.
It should be noted that Given the nature of this multiple-choice examination, candidates need
a) the BOE is examining candidates on the entire GCB/P syllabus, and to study the entire syllabus to maximise their chances of passing.
not just the revision notes; Companies are encouraged to ensure that the support and commitment
b) the pass mark for a multiple-choice examination, given the chance of they give to their examination candidates i.e. the quality of course
random selection of the correct answer, has by its very nature to be material, tutoring and mentoring, is always to the required standard.
much higher than for a traditional ‘narrative’ examination: whereas the
latter was set at 55%, the former requires 40 correct answers out of 60 Colin McCrorie

30 THE INSTITUTE OF BREWING & DISTILLING • EXAMINATION REPORT 2008

EXAM Booklet OCT 08: EXAM Booklet OCT 08 25/9/08 14:58 Page 31

General Certificate in Distilling Examination sequences provided that option.

All previous GCD papers have included questions on preparation or
November 2007 interpretation of graphical data. Preparation of graphs by candidates is no
The November 2007 examination was offered in three versions, one being longer possible within the constraints of multiple-choice format, but
the standard GCD. For the first time the GCDI was offered both in English deducing information from prepared graphs continued to perplex some
and Afrikaans, for the convenience of eight South African candidates. candidates. In the question based on.graphs of normal and faulty
Four candidates sat the standard GCD, two passing at Credit grade, but fermentations, the fall in pH was carefully drawn identically on both
unfortunately one failed. Results in the International version were much graphs but the graphs of yeast growth showed pitching rates of
less successful; only two of the 10 candidates passed, one at Credit grade. approximately 8 and 2 g/litre respectively. Even if candidates did not use
As usual, most of the candidates who failed nevertheless provided some g/litre in routine measurements at work, the four-fold difference should
very good answers, but not enough of them. have been the clue to the correct answer: insufficient pitching yeast. With
Previous reports have provided an opportunity for me to comment on the allowance of an average of 2 minutes per question, there is ample time
the more serious mistakes in the scripts, or perhaps just more commonly- to consider carefully all of the information provided.
occurring. This was mainly intended as advice to future candidates, so on That includes interpreting correctly the wording of the question. One
this occasion such a discussion would be pointless. As has been well IBD question which many candidates answered wrongly concerned triple
magazine The Brewer & Distiller International, future GCD examinations distillation, specifically on the principal difference between double and
will be entirely in the form of multiple-choice questions. triple in the hypothetical situation of distilling the same wash. Many
Candidates for the May 2008 examination will be advised individually candidates chose "triple distillation produces stronger whisky". It is true
of the new syllabus and examination arrangements, but it may be of that the new spirit is stronger, but after the necessary reduction, the
general interest to summarise the changes here. There will be only one maturation and bottling strengths of the whiskies will be the same. The
examination (equivalent to the previous GCDI) in which 40 multiple- correct answer was "triple distillation produces whisky with a lower
choice questions are based on those aspects of the syllabus which are content of low-volatile congeners": partly due to the greater rectification,
common to distilled spirits produced from grapes, sugar-cane molasses of and partly due to the proportionally greater post-distillation dilution,
cereal starch, and the other 20 examine the candidate's knowledge of only reducing the content of these congeners even more.
one of these specialisations. However, there will continue to be a choice of For some questions it was impossible to devise three plausible
answering either on maturation of "brown spirits" or on the production of "distractor" statements so the format was reversed to provide three correct
gin and vodka. Also, candidates from the whisky industry can choose and one wrong. Alternatively, candidates had to identify the statement
questions on the technology of either grain or malt distilling. least rather than most likely to be correct.
For some years now the number of multiple-choice questions in the Although both are legitimate types of question, that situation clearly
examination papers has gradually increased, without causing any obvious confused some candidates, not least in the question on the least effective
problem. So I am confident that the introduction of a completely multiple- source for recovering energy from hot water. I was surprised by the high
choice examination will be welcomed by candidates. proportion of answers naming a shell-and-tube condenser, which can be
operated to give high water temperature throughout distillation. In fact
Iain Campbell that is the best of the four named sources of recovered heat energy. I
sympathise with those who chose condensate from pot still heating coils
(probably re-used as top-up boiler water), but that was regarded as wrong
May 2008 since the question asked candidates to consider not only temperature and
Of the 108 candidates who sat the new multiple-choice Certificate volume, but also availability throughout distillation, which is true of coil
examination, 78 passed (72.2%). This is similar to the pass rates in the condensate. Since the volume of spent lees is relatively small, and
past two years of the old-style examination, and much better than the available only at the end of distillation, that was accepted as the correct
63.5% pass rate of 2005, the last time we had over 100 candidates. answer. That section also included a question on identifying the lowest
However, no Distinction grades and only 15 Credit grades (13.9%) are BOD of the following packaging wastes: bottle rinsing water, waste
poorer statistics than previously; perhaps the changed style of detergent, filter washings and spilt whisky (e.g. from leakage or broken
examination caused problems for some candidates. It is impracticable to bottles). I assume that the frequent choice of spilt whisky was based on the
publish the complete list of questions with their correct answers, not least reasoning that since spillage should not happen, then it should not
because we want to re-use as many as possible some time in the future! contribute to BOD. But the question concerned the actual BOD of these
The intention of each 4-part question was to provide one correct answer in four specified liquids, not the amount accumulated in a given time in a
association with three plausible but wrong statements. Perhaps many of well-run packaging operation. In fact, a whisky spillage, if it occurred,
these "distractors" were too plausible to candidates who were not would probably be the highest BOD on the list. On the reasonable
sufficiently knowledgeable of the topic of the question, but it is equally assumption that only new bottles are used, the clean rinsing water must be
possible that candidates did not read questions carefully enough to the lowest BOD.
appreciate exactly what was being asked. So I have chosen the following Although only a few questions and answers have been analysed for this
examples of questions which generated a high proportion of wrong report, I hope that they illustrate sufficiently the principles of answering
answers to illustrate the strategy of answering different types of multiple- multiple-choice questions. Essentially you have to read each question
choice question. very carefully, also any associated graph, sketch or table, to understand
Firstly, however, there were a number of questions where the correct what is required. Of course there was never any intention to mislead
answer could be identified by reasoning, even without previous candidates, but for some questions the response to a less than thorough
experience of the situation. One such example concerned the correct order reading might not be correct.
of the processes of blending, chill filtration and reduction to filling
strength for packaging. Obviously blending had to be first, to create a
single product for the other procedures, and only one of the four Iain Campbell

THE INSTITUTE OF BREWING & DISTILLING • EXAMINATION REPORT 2008 31

EXAM Booklet OCT 08: EXAM Booklet OCT 08 25/9/08 14:58 Page 32

Successful Candidates

The successful candidates from the 2008 Diploma and Master Brewer Examinations,
who meet all IBD criteria, are listed as follows:

MASTER BREWER EXAMINATIONS Stewart, Ross Gardiner ++ Southern

Steyn, Gary James Africa
Master Brewer – Module One Passes
Wright, Brad International
NAME SECTION
Alobwede Metuge, Charles Africa
Master Brewer Module Four passes
Audet, Travis International
Adadevoh, Eric Sewonu Africa
Bajner Robert, Erno Africa
Baxter, David James Connel ++ Midland
Broadbent, Jonathan Paul Midland
Bell, Irene Asia Pacific
Brown, Lianne Great Northern
Davies, Robert Edward ++ Irish
Cousins, Winston Anthony International
Du Toit, Malcolm A Africa
Donehower, Weston John International
Fitzgerald, Fergus Richard ++ Southern
Gilleland, Emma-Jane Midland
Harrington, Criona Threase Irish
Harrington, Criona Threase Irish
Kilcullen, Stephen Irish
Hayward, Monika International
McFarlane, Angus Black Africa
Impey, Michael Martin Irish
Nagandi, Saphan Africa
Kilcullen, Stephen Irish
Nisbet, Robert Patrick Southern
Leslie, Michael Patrick International
Tanner, Brigid Catherine ++ Irish
Marchetti, Marcello Asia Pacific
McLean, Kevin Ian Maurice International
Master Brewer Module Five passes
Ngubane-Ngwenya, Blessing Africa
Appiah-Danquah, Martin ++ Southern
Oates, Neil Anthony International
Baxter, David James Connel ++ Midland
Parkinson, Philip James Midland
Bihl-Kirkwood, Georgia Gladys Africa
Pitso, Gabriel Africa
Butler, Bogart Africa
Radegonde, Andrea Africa
Davies, Robert Edward ++ Irish
Sneddon, Ewan Southern
Fitzgerald, Fergus Richard ++ Southern
Iyogbon, Hamilton Ehidiamhen Africa
Master Brewer Module Two passes
Patkar, Keshav Laxminarayan Asia Pacific
Bajner, Robert Erno Africa
Peters, Ann Margaret ++ Southern
Cousins, Winston Anthony International
Ramshaw, James Edward Michael ++ Midland
Dickinson, Rebecca Jean International
Sparks, Donovan Roy ++ Africa
Herholdt, Tanith Africa
Stewart, Ross Gardiner ++ Southern
Impey, Michael Martin Irish
Stradiotto, Steven ++ International
Kenmogne, Maurice Africa
Tanner, Brigid Catherine ++ Irish
Kwarciak, Dominika Great Northern
Mahesh, Rajamanickam Asia Pacific
++ has passed all modules of the M.Brew by accumulation
McLean, Kevin Ian Maurice International
Parkinson, Philip James Midland
Radegonde, Andrea Africa
DIPLOMA IN BREWING EXAMINATION
Saha, Surajit Asia Pacific
Taylor, Joshua Fraser Southern Dipl. Brew Modules One, Two & Three Passes
Walton, Emma Louise Great Northern Birdwell, Scott International
Caire, Justinian International
Master Brewer Module Three passes Dehlinger, Eva International
Baxter, David James Connel ++ Midland Delaney, Byron International
Britt, Alison Southern Eggemeyer, Kevin International
Coulson, Adam Nathaniel Asia Pacific Foster, Jeffrey International
Hamilton, Graeme William Midland Jovancic, Bjanka Africa
Hayes, Keith Great Northern Kuchle, Chase International
Iyogbon, Hamilton Ehidiamhen Africa Maharaj, Suraksha Africa
Jennings, Belinda Southern Marlow, Lisa Marie Irish
McGregor, Emily Joan Great Northern Martin, Ashley International
Morley, Shane Kelvin Asia Pacific Meeker, William International
Ngubane-Ngwenya, Blessing Africa Moothi, Kapil International
Ramshaw, James Edward Michael ++ Midland Nordman, Joel Asia Pacific
Sheils, Rory Irish Oddone, Gian Michele International

32 THE INSTITUTE OF BREWING & DISTILLING • EXAMINATION REPORT 2008

EXAM Booklet OCT 08: EXAM Booklet OCT 08 25/9/08 14:58 Page 33

Oliver, Donald International Laumann, Jacqueline International

Passau, Andrew Hardy Asia Pacific Legnard, John International
Poor, Elysia Alberta International Luedtke, Robin International
Schultz, Nikolaus International Malloy, Todd International
Schurman, Timothy International Mann, Peter James Southern
Weisel, Seth International Mata Osoro, Paula Southern
Wieland, Bernhard Elliot International May, Chloe Southern
Willemse, Nathaniel Africa Mcginty, Patrick Joseph Midland
Medronho, Paula Alexandra Africa
Diploma in Brewing Module One passes Merrington, Peter Anthony Asia Pacific
Adedayo, Timothy Oludare Africa Mogorosi, Mildred Africa
Adodo, Oluyomi Africa Morgan, Haydon Peter Asia Pacific
Akman, Michael Africa Morgan-Jones, Andrew Asia Pacific
Alvarez Silva, Ignacio Jesus International Mueller, John International
Badura, Michael Irish Mulu, Mary Mutanga Africa
Bailey, Monique Roxanne ++ International Muriithi, Esther Wambui Africa
Baldry, Dawn Marie Southern Ndlovu, Khumbula Africa
Baptista, Sergio Costa Great Northern Ngoile, Eric Wilhelm International
Bellham, David John Midland Ngoma Mapenda, Esther Africa
Benson, Michael Andrew Great Northern Nine Rey, Maria Victoria Great Northern
Bergin, Ailish Irish Numair, George International
Berner, Jacobus Africa Nyam A Mpon, Guy Thierry Africa
Bhardwaj, Sharad Asia Pacific O Driscoll, Bernadette Irish
Bharne, Pankaj Asia Pacific O'Connor, Fearghal Patrick ++ Irish
Billig, Marcus Charles Midland Ogunwale, Gbenga Adeniyi Africa
Boatemaah, Barbara Africa Omosanya, Lateef Oyetunde Africa
Brestovansky, Jan Irish Oshiegbu, Osemeke Africa
Bricknall, Sarah Asia Pacific Parker, Robert James International
Broadhead, Sarah Helen Great Northern Parnis, Craig John Southern
Burch, Christopher International Parsons, Patrick Roy ++ Irish
Calman, Nathan Garth Asia Pacific Pelt, Rashaad International
Carlot, Lucie International Perkins, Todd Philip International
Catala, Miguel International Quinn, Kevin Scottish
Chauvin-Schera, Celine International Rick, Justin International
Clarke, Richard ++ Irish Rogers, David Asia Pacific
Coffey, Dayton Joseph Asia Pacific Rust, Jason Bert International
Cooney, Carl Irish Schrama, Inge Joanna International
Crawford, Lindsay Matthew Asia Pacific Scott Paul, Daniel Great Northern
Cressey, Ian Anthony ++ International Seddon, Lewis Asia Pacific
Crutchfield, Evan International Sharma, Raj Kumar Asia Pacific
Curran, Greg International Short, Alan ++ Great Northern
Curren, Richard James Asia Pacific Shuell, Iain Harry Great Northern
Dallies, Nathalie ++ International Simpson, Peter Irish
Dambergs, Kai Robert Asia Pacific Smith, Julie E ++ International
De Jager, Louis Richard Africa Sturman, Anna Victoria Great Northern
Deenanath, Evanie Devi International Tang, Samuel Chei-kit Asia Pacific
Dolbel, David Southern Thadel, Manoj Parameshwara Asia Pacific
Durgin, William Smith International Thomas, Jody ++ Asia Pacific
Gross, Cathia International Tripathi, Arijit Asia Pacific
Gupta, Vishnu Asia Pacific Tucker Alexander
Gutfreund, Laurence International Charles Asia Pacific
Hayes, Matthew John Southern Uherova Alexandra Irish
Hettinger, James W International Upadhyay, Ravindra Nath Asia Pacific
Howard, Samantha Lee Asia Pacific Vaitilingom, Marc Michel ++ International
Howley, Joann Irish Vaughan, Caolan Gerard Asia Pacific
Hughes, Mark International Welby-Solomon, Marvin Africa
Kapoko Tagne, Innocent ++ Africa Wijsman, Theo International
Kaporina, Elena International Ypenburg, Dirk Jan Nicolaas International
Karadsheh, Yazan International
Lanthois, Ben Kevin Asia Pacific

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EXAM Booklet OCT 08: EXAM Booklet OCT 08 25/9/08 14:58 Page 34

Diploma in Brewing Module Two passes Spencer, Thomas Midland

Andrews, Clinton Brett ++ Asia Pacific Sproats, Christopher Asia Pacific
Benne, Patricia Lynn ++ International Still, Hayden Edward ++ Asia Pacific
Bhardwaj, Sharad Asia Pacific Takurukura, Gordon Great Northern
Bharne, Pankaj Asia Pacific Thadel, Manoj Parameshwara Asia Pacific
Botha, Marianka Lynette ++ Africa Thomas, Louise Southern
Breish, Russell International Thorn, Ian John Southern
Bricknall, Sarah Asia Pacific Toose, Natalie Renee Asia Pacific
Brown, Kisha-Ann International Transmantiner, Eva ++ International
Casey, John Thomas Irish Ushi, Osmund Emeka Africa
Charleston, Nicola ++ Scottish Vel, Brian Michel International
Cherukut, Alfred Stefan Africa Vickers, Jemima Victoria Southern
Clarke, Richard ++ Irish Walker, Stefan John ++ Asia Pacific
Cressey, Ian Anthony ++ International Willcock, Chris Joel Asia Pacific
Curran, Greg International
Currie, Margaret Lilian Asia Pacific Diploma in Brewing Module Three passes
De Bordenave, Channing Williams International Afolabi, Olusesan Samuel Africa
Eder, Michael Josef International Aldred, Peter ++ Asia Pacific
Egan, Lawrence ++ Irish Alvarez Silva, Ignacio Jesus International
Eribankya, Nicholas ++ Africa Bailey, Monique Roxanne ++ International
Grant, Matthew Paul ++ Irish Balami, Daniel Gombe ++ Africa
Hettinger, James W International Benne, Patricia Lynn ++ International
Howard, Malcolm John ++ Asia Pacific Bennett, Mark ++ Great Northern
Hughes, Mark International Bhat, Balachandra ++ International
Ivie, Mark ++ International Bhowruth, Veekash Southern
Joshi, Atul Asia Pacific Botha, Marianka Lynette ++ Africa
Kapoko Tagne, Innocent ++ Africa Botwright, Benjamin James ++ Midland
Lash, Duncan Thomas Irish Boudler, Sabrina ++ Africa
Leclaire, Jessica Southern Brittle, William Ross International
Legnard, John International Burch, Christopher International
Leichel, John International Casey, Troy ++ International
Lim, Chui Wan Asia Pacific Catala, Miguel International
Mckibbin, Samuel Alan Irish Cawley, Mark ++ Irish
Medronho, Paula Alexandra Africa Chesterman, Miles Robert William ++ Southern
Minihane, Shane Irish Coetzee, John Claude ++ Africa
Morrow, Ryan James Robert International Cooper, Zoe Midland
Moxom, Richard John ++ Irish Cottam, Joseph L ++ International
Muriithi, Esther Wambui Africa Cullen, Emma ++ Irish
Musonda, Wellington Africa Dallies, Nathalie ++ International
Mwanja, Samuel ++ Africa De Jager, Maret ++ Africa
O'Beirne, Kieran ++ Irish Draper, Ivan John Midland
O'Brien, John Irish Du, Yuguo ++ Asia Pacific
O'Connor, Fearghal Patrick ++ Irish Egan, Bryan Daniel ++ International
O'Meara, Ryan James Asia Pacific Felaar, Timothy Arnold ++ Africa
Oshiegbu, Osemeke Africa Ferguson, Jaeanne Anthea Oline ++ International
Paff, Emily Jane Asia Pacific Fidler, Greg ++ International
Parsons, Patrick Roy ++ Irish Fox, Sarah Louise ++ Irish
Pawlowsky, Karin Marie Daniele Southern Gautreau, Paul ++ International
Perez, Belen Southern Goodall, Adam Anthony Great Northern
Perkins, Todd Philip International Goodwin, David ++ Great Northern
Pradeep, Sinha Kumar Asia Pacific Gosling, Andrew John ++ Midland
Pretorius, Barend Johannes Voster Africa Graham, Damian International
Rust, Jason Bert International Grootendorst, Carl Eric Oliver International
Sapkota, Jaya Bahadur Asia Pacific Gupta, Vishnu Asia Pacific
Schofield, Vanessa Helen Southern Hadley, Tully Ceman Patrick ++ Asia Pacific
Searle, Bradley David Asia Pacific Heffernan, Robert Joseph Irish
Sharma, Raj Kumar Asia Pacific Howard, Malcolm John ++ Asia Pacific
Shashikala, Bijageri Asia Pacific Joseph, Egangu Africa
Shijagurumayum, Gogochandralal Asia Pacific Kaporina, Elena International
Smith, Julie E ++ International Kayange, Kelvin ++ Africa

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EXAM Booklet OCT 08: EXAM Booklet OCT 08 25/9/08 14:58 Page 35

Khin, Aung ++ Asia Pacific Flaherty, Aaron Charles Frederick Scottish

Kumar, Ganesh ++ International Hall, Stephen John Scottish
Laurentiu, Polschi Eduard ++ International Harrison, Elaine Irish
Lawrence, Mickellia Guvannie ++ International Macinnes, Norman MacLean Scottish
Lewin, David Roger ++ Southern McCulloch, Andrew James Scottish
Lewis, Elizabeth-Jayne ++ Asia Pacific McIntyre, Sandy Scottish
Madigoe, Ezekiel Makwadinkga International McNair, Ian Alexander Scottish
Maphutha, Kwena Selby International McNally, Darryl Joseph Irish
Marriott, Louise Southern Tapsi, Prasad ++ Asia Pacific
McLean, Jacob Alexander ++ International Thomson, John Andrew Scottish
Mehrtens, Kathryn Charlotte Louise ++ Asia Pacific Wright, Holly Annabell Scottish
Moon, Stuart Southern
Ndlovu, Khumbula Africa Diploma in Distilling - Module Two passes
Nxusani, Apiwe Philela ++ Africa Anderson, Russell Ian Scottish
Nyam A Mpon, Guy Thierry Africa Burke, Daniel Irish
Oghonim, Onyelelue Everest ++ Africa Conway, Niall Irish
Oiko, Samuel ++ Africa Geddes, Caroline Scottish
Okol, Moses ++ Africa Hall, Stephen John Scottish
Omamogho, Arho Harrison ++ Africa Jack, Frances Ruth Scottish
Onuoha, Benneth Chibueze ++ Africa Macinnes, Norman MacLean Scottish
Pedder, James Southern Martin, Caroline Mitchell Scottish
Prior, Miss Irish McCarthy, Noirin Ide Irish
Ratnayake, Amalka Sudeera Kumari ++ Midland Mcguigan, Frank Irish
Robinson, Louise ++ Asia Pacific Power, Michael Irish
Rosti, Johannes ++ International Savage, Fiona Irish
Sandford, Jennifer Anne Irish Thompson, Marie Anne Scottish
Sheils-Ryan, Paula Irish
Small, Stephanie Ann ++ International Diploma in Distilling - Module Three passes
Smith, Anthony Michael ++ Southern Dean, Ian Stuart ++ Scottish
Smith, Brian ++ Southern Ferguson, Jane ++ Scottish
Sodha, Fateh Singh ++ International Lindsay, Roy F ++ Scottish
Stephens, Jeremy Matthew ++ Scottish Mclean, Mark Bruce ++ Scottish
Stewart, Neil Sedaka ++ International More, Carol Scottish
Tetai, Reremoana ++ Asia Pacific Tapsi, Prasad ++ Asia Pacific
Thomas, Jody ++ Asia Pacific
++ has passed all modules of the Dipl.Distil by accumulation
Thompson, Kerryn ++ Asia Pacific
Tomblin, Steven Andrew ++ Southern
Upadhyay, Ravindra Nath Asia Pacific
DIPLOMA IN PACKAGING EXAMINATION
Ushi, Osmund Emeka Africa
Van Dieren, Teunis International Diploma in Packaging passes
Werro, Graham ++ Southern Appelbee, James + Midland
Williams, Kelly Lindsay ++ International Austin, Michael Collin + International
Wilson, Alan William ++ Asia Pacific Elson, Robert Mark + Midland
Wilson, Nkrumah International Glenn, Ryan John + Southern
Wood, Iain James Irish Morris, Steve James + Southern
Yates, Elisabeth Anne ++ Southern Nduati, David Thiong'o + Africa
Yeoh, Bun Hooi ++ Asia Pacific Paul, Lachlan Kenneth + Asia Pacific
Potter, Wayne Anthony + Asia Pacific
++ has passed all modules of the Dipl.Brew by accumulation
Rathbone, Sean Graham + International
Scheleyer, Samantha Kathryn + Asia Pacific
Callison, Andrew Iain +++ Midland
DIPLOMA IN DISTILLING EXAMINATION
Etheridge, Ashley +++ Midland
Dipl.Distil Modules One, Two and Three – Passes Gregory, Tupu Arthur +++ Asia Pacific
Whyte, Tracey Scottish Johnstone, Adrian +++ Midland
Quinn, Christopher Michael +++ Midland
Diploma in Distilling - Module One passes
+ Candidate passed Module 1
Carr, Lisa Marie Scottish
+++ Candidate passed Module 2
Carson, James Scottish
Clark, Christopher Anthony Scottish
Duguid, Caroline Scottish

THE INSTITUTE OF BREWING & DISTILLING • EXAMINATION REPORT 2008 35

EXAM Booklet OCT 08: EXAM Booklet OCT 08 25/9/08 14:58 Page 36

Institute of Brewing & Distilling

Africa Section

IBD Africa Conference and Exhibition

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36 THE INSTITUTE OF BREWING & DISTILLING • EXAMINATION REPORT 2008