Edith Cowan University Research Online Theses: Doctorates and Masters Theses 1-1-1998 Development of a quality assurance plan for a microbrewery Matthew J. Williams Edith Cowan University Follow this and additional works at: https://ro.ecu.edu.au/theses Part of the Operational Research Commons Recommended Citation Williams, M. J. (1998). Development of a quality assurance plan for a microbrewery. https://ro.ecu.edu.au/theses/979 This Thesis is posted at Research Online. https://ro.ecu.edu.au/theses/979 Edith Cowan University Copyright Warning You may print or download ONE copy of this document for the purpose of your own research or study. The University does not authorize you to copy, communicate or otherwise make available electronically to any other person any copyright material contained on this site. You are reminded of the following: Copyright owners are entitled to take legal action against persons who infringe their copyright. A reproduction of material that is protected by copyright may be a copyright infringement. Where the reproduction of such material is done without attribution of authorship, with false attribution of authorship or the authorship is treated in a derogatory manner, this may be a breach of the author’s moral rights contained in Part IX of the Copyright Act 1968 (Cth). Courts have the power to impose a wide range of civil and criminal sanctions for infringement of copyright, infringement of moral rights and other offences under the Copyright Act 1968 (Cth). Higher penalties may apply, and higher damages may be awarded, for offences and infringements involving the conversion of material into digital or electronic form. Development of a quality assurance plan for a microbrewery By Matthew J. Williams A research project submitted in fulfilment of the requirements for the award of Master of Applied Science, in the Department of Consumer Science, Edith Cowan University, Western Australia. April 1998 EDITH COWAN UNIVERSITY dBRARY USE OF THESIS The Use of Thesis statement is not included in this version of the thesis. CONTENTS DEFINITION OF TERMS ................................................................................................... i ABSTRACT ....................................................................................................................... iv DECLARATION ................................................................................................................. V ACKNOWLEDGEMENTS ............................................................................................... vi SECTION 1: INTRODUCTION ......................................................................................... 1 SECTION 2: LITERATURE REVIEW .............................................................................. 4 2.1 Quality assurance ....................................................................................................... 4 2.1.1 Definition of quality ............................................................................................ 4 2.1.2 Quality as a business strategy .............................................................................. 5 2.1.3 Major approaches to quality assurance ................................................................ 7 2.1.3.1 Total Quality Management ............................................................................ 7 2.1.3.2 Standards-based approach ............................................................................. 8 2.l.3.2(a) National quality awards ......................................................................... 8 2. l.3.2(b) ISO 9000 ................................................................................................ 9 2.1.4 Criticisms of current quality assurance methods ............................................... 11 2.2 Microbreweries ........................................................................................................ 12 2.2.1 Definition of microbrewery ............................................................................... 12 2.2.2 Manufacturing process of microbreweries ........................................................ 13 2.2.2.1 Milling ......................................................................................................... 13 2.2.2.2 Mashing ....................................................................................................... 14 2.2.2.3 Sparging/lautering ....................................................................................... 15 2.2.2.4 Wort boiling ................................................................................................ 16 2.2.2.5 Wort processing ........................................................................................... 17 2.2.2.6 Fermentation ................................................................................................ 18 2.2.2.7 Finishing ...................................................................................................... 19 2.2.2.8 Packaging .................................................................................................... 21 2.2.3 Consolidation of the brewing industry .............................................................. 22 2.2.4 The Beer Renaissance ........................................................................................ 23 2.2.5 Microbreweries in Australia .............................................................................. 24 2.2.6 Factors influencing the potential expansion of microbreweries ........................ 25 2.2. 7 Reasons for the lack of quality assurance in microbreweries ............................ 26 2.3 Hazard Analysis Critical Control Point (HACCP) .................................................. 27 2.3.1 HACCP Concept ............................................................................................... 27 2.3.2 Relationship Between HACCP and ISO 9000 ................................................... 30 2.3.3 Application of the HACCP concept to food quality issues other than safety .... 31 SECTION 3: METHOD .................................................................................................... 34 3.1 Developing the quality assurance plan adopting the HACCP concept .................... 34 3.1.1 Assemble the team to develop the plan ......................................................... 34 3.1.2 Identify quality issues to address ................................................................... 34 3.1.3 Construct the flow diagram ........................................................................... 35 3.1.4 Conduct the hazard analysis .......................................................................... 36 3.1.5 Determine Quality Control Points (QCPs) .................................................... 36 3.1.6 Establish control at QCPs .............................................................................. 39 3.1.7 Establish method of verification ................................................................... 40 3.1.8 Construct record sheets and record keeping procedures ............................... 41 3.2 Pilot test ................................................................................................................... 41 SECTION 4: RESULTS AND DISCUSSION .................................................................. 44 4.1 The quality assurance plan ....................................................................................... 44 4.1.1 The study team ................................................................................................... 44 4.1.2 Quality issues ..................................................................................................... 44 4.1.3 Process flow ....................................................................................................... 47 4.1.3.1 Floor plan .................................................................................................... 47 4.1.3.2 Description of plant machinery ................................................................... 49 4.1.3.3 Cleaning of plant machinery ....................................................................... 49 4.1.3.4 Flow diagram ............................................................................................... 50 4.1.4 Hazard analysis .................................................................................................. 53 4.1.4.1 Receipt of raw materials .............................................................................. 53 4.1.4.2 Storage of raw materials .............................................................................. 56 4.1.4.3 Processing of mains water ........................................................................... 56 4.1.4.4 Milling ......................................................................................................... 57 4.1.4.5 Mashing ....................................................................................................... 57 4.1.4.6 Reprocessing of water for sparging ............................................................. 58 4.1.4. 7 Sparging/lautering ....................................................................................... 58 4.1.4.8 Wort boiling ................................................................................................ 59 4.1.4.9 Wort cooling and aeration ........................................................................... 60 4.1.4.10 Fermentation