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General Certificate in Packaging (Spirits) GCP(S)

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General Certificate in Packaging (Spirits) GCP(S) Qualifications General Certificate in Packaging (Spirits) GCP(S) Learning Material © Institute of Brewing and Distilling 2011 GCPS Revision Notes Version 1 August 2011 Section 1 An Overview of Spirits and Spirits Packaging. 1.1 Definition of Spirit and Spirit Type. As an example of raw material restrictions, the mash for a scotch malt whisky must be 100% barley malt with no Introduction. adjuncts, and the malt itself has some restrictions For the purposes of consumable drinks, spirits are a liquid associated with its production (e.g. the use of gibberellic containing ethanol which are produced by distilling the acid in the malting process is not permitted). For a scotch products of a fermented grain, vegetable or fruit mash. The grain whisky, the mash is likely to constitute a small grain, vegetables and fruit are a source of starch and sugars amount of malt (to supply the necessary enzymes for which are fermented by yeast (primarily Saccharomyces sp.) conversion of starch to sugar) and a large quantity of a to an alcoholic liquid usually no more than 12-15% abv. To grain adjunct such as maize or wheat. achieve an alcoholic content beyond this is not possible by fermentation alone, as excess ethanol has a toxic effect on The traditional terms “brown” and “white” spirits are yeast cells. It is therefore necessary to concentrate the loosely associated with the use of an ageing process or not, alcoholic content of the liquid by distillation. i.e. brown spirits are aged in wood whereas white spirits are not. Flavoured spirits are becoming increasingly The production of spirits is highly regulated, in most popular with consumers, and allow producers to clearly countries requiring a licence to produce, and tax duty is differentiate their products from competitors. payable to central government on spirits produced. 1.2. The Definition of Spirits Packaging and Traditional pot still distillation is a batch process where the General Aims liquid is distilled usually twice, and sometimes three times, to achieve the desired alcoholic content in the distillate. The general aims of packaging spirits are to:- Column distillation using a Coffey still is a continuous • Provide the consumers with spirits in a convenient process and has the ability to produce distillates of much package of their choice. higher alcoholic content than pot still distillation. • Ensure that the quality of the spirits is protected during packaging operations. • Ensure that the quality of the product is protected during its shelf life (for ready to drinks; high strength SUGAR YEAST ALCOHOL spirits have no defined shelf life) • Assist in the marketing of the product by presenting the package in an attractive form. Different types of Spirits • Ensure that the requirements of the relevant Regardless of how the distillation is done, much of the authorities (for example, Excise) are met. differentiation of spirits occurs as a result of the materials • Control the costs of packaging to an economic used in the mash, and in the methods used to finish the minimum. spirit once it is distilled. Certain variants of spirits are • Protect the health and safety of the people who work restricted in terms of the use of raw materials. Some in the packaging areas and the consumers. examples: Many of these aims are required so that “due diligence” Whisky : a fermented grain mash, aged in wood once with regard to safety of product, consumer and operator is distilled. Grains used, ageing, and type of wood used vary ensured. depending on country of production. The procedures used to ensure that these aims are met are Vodka : a fermented grain and / or vegetable mash, no detailed in the tables below:- ageing process, possible use of flavourings. How to provide the consumers with a convenient package Gin : a fermented grain and or / vegetable mash, no ageing of their choice. process, flavourings (botanicals, primarily juniper berries) added prior to distillation. Package Procedure. type. Brandy : a fermented grape mash (though other fruits are Non- Choice of different sizes. now commonly used), some types are aged post distillation returnable Choice of different shapes. but many have caramel added to give the appearance of bottle. Choice of different glass colour. wood ageing. Choice of different glass weight. Choice of different pack/box etc. Rum: a fermented sugar cane / molasses mash, distilled and Can. Choice of different sizes. aged in wood Choice of different ‘end’ opening. 2 General Certificate in Packaging (Spirits) How to ensure that the quality of spirits is protected How to assist in the marketing of the product by during packaging. presenting the package in an attractive form. Package Procedure. Package Procedure. type. type. Non- • Ensure supply mains to filling Non- • Maintain high standards of labelling. returnable equipment are rinsed or cleaned to returnable • Minimise or eliminate damage to bottle. prevent cross contamination between bottle. closures (decorative and otherwise) products. from the production process. • Ensure bottles are cleaned successfully • Minimise or eliminate bottle scuff or (air or water rinse) prior to filling. damage from the production process. • Use HACCP procedures on the filling • Ensure that the multipacking and line and liquid production plant. shrink film operations are run • Monitor spirit quality from finished effectively. product tank to final package. • Ensure that any secondary packaging • Ensure that hygiene standards for operations are run effectively. bottling plant are maintained. Can. • Ensure that the multipacking and • Pasteurise low alcohol ready to drink shrink film operations are run products to prevent microbiological effectively. spoilage. • Ensure that secondary packaging Can. • Ensure supply mains to filling operations are run effectively. equipment are rinsed or cleaned to prevent cross contamination between How to ensure that Statutory Taxation (Excise) products. requirements are met. • Ensure cans are cleaned successfully (air or water rinse) prior to filling. Package Procedure. • Use HACCP procedures on the filling type. line and liquid production plant. Non- • Ensure that bottles are not over filled. • Monitor spirit quality from finished returnable • Ensure that the label states the product tank to final package. bottle. correct contents and alcohol level. • Ensure that hygiene standards for • Ensure that alcohol levels are canning plant are maintained. analysed in package and that the • Pasteurise low alcohol ready to drink relevant records are kept. products to prevent microbiological • Ensure that full package level spoilage. inspection is effective and that the relevant records are kept. How to ensure that the quality of ready to drinks (RTDs) is Can. • Ensure that cans are not over filled. protected during its shelf life. • Ensure that the can states the correct contents and alcohol level. Package Procedure. • Ensure that alcohol levels are type. analysed in package and that the Non- • Reduce air pickup during bottling to a relevant records are kept. returnable minimum. • Ensure that full package level bottle. • Pasteurisation (sterile filtration is inspection is effective and that the usually unsuitable for these products) relevant records are kept. for microbiological stability. Over pasteurisation reduces shelf life. • Ensure that hygiene standards for bottling plant are maintained. Can. • Reduce air pickup during canning to a minimum. • Pasteurisation or sterile filtration for microbiological stability. Over pasteurisation reduces shelf life. • Ensure that hygiene standards for canning plant are maintained. Revision Notes Version 1 August 2011 3 How to ensure that the requirements of “Trading How to protect the Health and Safety of the people who Standards” are met. work in the packaging areas. Package Procedure. Package Procedure. type. type. Non- • Ensure that bottles are not under Non • Protect against broken glass. returnable filled. returnable • Protect against noise. bottle. • Ensure that the label gives the correct bottle. • Protect against slips trips and falls. information. • Protect against machinery accidents. • Ensure that full package inspection • Protect against high carbon dioxide and analysis is effective and that the levels and against dilution of oxygen relevant records are kept. in air by nitrogen (where appropriate Can. • Ensure that cans are not under filled. for the product) • Ensure that the can label gives the Can. • Protect against noise. correct information. • Protect against slips trips and falls. • Ensure that full package inspection • Protect against machinery accidents. and analysis is effective and that the • Protect against high carbon dioxide relevant records are kept. levels and against dilution of oxygen in air by nitrogen (where appropriate Please note that national law and local regulations will vary for the product) in different countries and that various authorities may differ in their interpretation of the law. How to control the costs of packaging to an economic minimum. How to ensure that the Consumer Safety requirements are met. Package Procedure. type. Package Procedure. Non- • Operate the plant effectively through type. returnable effective maintenance, planning and Non- • Ensure that empty bottle inspection bottle. staff training to achieve the specified returnable and the reject system is effective and throughput. bottle. that the relevant records are kept. Can. • Reduce spirits losses by controlling fill • Ensure that bottle rinsing and plant heights and
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