Bergenbier

Ploiesti Brewery

CONTENT
Chapter

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Manual HACCP

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Date Published

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CONTENT

1.
1.1
1.2
1.3
1.4
2.
3.
3.1
4.
5.

17

COMPANY PROFILE
Contact elements
History
Field of activity
Management team
HACCP TEAM DESCRIPTION
PRODUCTION
Flow Diagrams
HAZARD ANALYSIS
CCP SUMMARY

1. COMPANY PROFILE
1.1 Contact elements
Bergenbier Ploiesti Brewery is located in Ploiesti, Romania on Cantacuzino Street no. 287

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Bergenbier BreweryPloiesti

1.2 History
The birth of Bergenbier Brewery Ploiesti
Interbrew Romania
Interbrew entered the Romanian market in April-Mai 1994, and bought two breweries within two weeks
one in Baia Mare (Proberco) with the existing brand Hopfenkonig and one in Blaj (BIB) where the
Bergenbier brand was launched. At the same time Interbrew created a distribution company (ITW). Within
three to four years, Interbrew developed his brands to the point in May 1997 when Stella Artois was
launched on the local market.
Since Interbrew Romania was a fast growing company, it was dealing with a capacity issue at that time.
Because 60 percent of its sales are in the south-eastern region of Romania, Interbrew started the process
of building a new brewery in Bucharest.
December 2002, CDN, Proberco and BIB decided to join in one company keeping the name of CDN.

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A new brand, famous German beer Becks became one of the brands which are brewed by IEB. It was
launched in May 2003 and had a great success (Becks beer respects the German law of beer purity).
Since September 2003 CDN changed the name into Interbrew Romania SA
Efes
Efes is the biggest beer company in Turkey. They are on the Romanian market since 1992 and are
producing Efes Pilsener in Romania since 1997 trough a joint-venture with the Cozla brewery in Piatra
Neamt.
Even though it wasnt doing too well in terms of sales, Efes became in 1998 operational with a brand new
brewery in Ploiesti, considered in terms of technology as the best in Central Europe.
Joint Venture
Very soon Interbrew and Efes realized they could do things together and find a better way to deal with
common problems. There was Interbrew with his low capacity problems and Efes with his over
capacity problems so they decided to join forces.
At the beginning of 1999, Interbrew entered in a joint venture with Efes, which brought it its third brewery
in the town of Ploiesti- the INTERBREW EFES BREWERY.
August 2006 InBev bought the remaining 50% of EFES shares in IEB with full control of Interbrew Efes
Brewery.
Starbev - in December 2009 was established the Starbev Company, after CVC bought from Inbev the plant
from CE
Bergenbier SA, Ploiesti Brewery in 1.03.2010 the company name was changed from Inbev Romania to
Bergenbier SA
April 2012 MolsonCoors Company bought the Starbev Company
When it was established in 1998, the brewery consisted of:
Brewhouse
1
Fermentation
18 cylindro-conical vessels
Filtration
1 Steinecker filtration line , with kieselghur
8 bright beer tanks
Packaging
1 Krones bottle line with tunnel pasteurization
1 can line with tunnel pasteurization
1 keg line with flash pasteurisation
New investments in 2006 and 2007; brewery capacity in the end of 2007, 3.1 mill.hl/year.
-2006 :
Packaging
-new PET line
-2007 :

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Brewhouse
-power mill
-mash convertor
-lauter tun
Fermentation area
-new CCT``s (6 units)
-one green beer transfer line with new centrifuge
Filtration area
-one filter line 750hl/h
-new BBT`s (6 units)
Utilities area
-1 air compressor
-one cooling compresor
-one CO2 compresor
New investments in 2008: increase brewery capacity to 3.7 mil hl/year
Brewhouse
Prephop installation
1 New Brewhouse
Fermentation
New CCTs (9 units)
Filtration
Up-date the filter line with a kieselghur option
3 new BBTs
Packaging
New Krones bottling line with flash pasteurization
Utilities:
New waste water treatment station not yet in function (investment postponed)
New investments in 2009:
Fermentation
2 new yeast storage tank
Filtration
New dearated water installation with 2 dearated water storage tanks
New beer & syrup installation for Becks Green Lemon production
3 new BBTs
Packaging
1 Sidel canning line with tunnel pasteurization
1 Sidel PET line with flash pasteurization
Upgrade kegging line with 2 new filling lines
Utilities
New CO2 recovery plant
New water treatment station

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Manual HACCP

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Rev. No.

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Date Published

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New investments in 2012:

Brewhouse
1 Silo for wheat malt
1 mill for coriander seeds
installation for pection dosage in wort for BB wheat
Fermentation
4 new CCTs
New investments in 2013:
Filtration
New beer &syrup installation for Bergenbier Fresh Lemon and Bergenbier Fresh Grapefruit production

3.2 Field of activity

The Romanian beer market is a very interesting one.
An increase in beer consumption per capita, together with higher expectations and a more sophisticated
demand of consumers is to be expected in the next few years.
Raw materials and materials used for beer production are:

Malt from barley

- import / local
Barley
- import / local
Maise
- local
Fructose
- import
Hop pellets
- import
Hop extracts
- import
Water from own wells and city water distribution
Culture yeast import yeast culture prepared in own propagation station
Fruit concentrates and bases - import
Filter aids
- import
Kieselguhr, PVPP
- import
Bottles
- import
Cans
- import / local
Preforms
- local
Kegs
- import
Labels
- local
Caps
- import / local

Seven segments can be distinguished in the Romanian beer market: Specialitees; International premium;
Local premium; Core lager; Value brands, Mix beers and the alcohol free segment

Brewery Ploiesti produces the following beer brands:

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Manual HACCP

QUAL.PLS.FS.001
Rev. No.

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Date Published

09/10/2007

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Bergenbier
Bergenbier Nefiltrata din grau
Staropramen
Lowenbrau
Noroc
Stella Artois
Beck`s
Bergenbier Nonalcoholic
Stella Artois Nonalcoholic
Becks Green Lemon
Bergenbier Fresh Lemon
Bergenbier Fresh Grapefruit
Bergenbier Fresh Grapefruit Non-alcoholic

From the process, there are resulting the following by-products:

Spent grains
Spent yeast

Brand Portofolio locally produced

Marius Pirvu
Plant Manager
Carmen Bako
Assistant to Plant
Manager

Manuela Nastasia
Quality Manager

Edvin Moldovan
Production Manager

Marius Pirvu
TS Manager

Valentin Cocos
Packaging Manager

TBD
Chief Accountant

3.3 Management Team

Stefania Cotoapa
Financial Controller

Patricia Bazna
Human Resources
Manager
Laurentiu Olaru
ES Manager

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2. HACCP TEAM DESCRIPTION

3. PRODUCTION
3.1 Flow Diagrams
4. SPOt.QUAL.3.1.4.2.HACCP risk analysis overview.xls
5. CCP SUMMARY

09/10/2007

Local

REFERENCE

Manual HACCP

QUAL.PLS.FS.001
Rev. No.

17

Date Published

09/10/2007

Local

Document History
Version

Author

Date

1.0

Laura Neagu

10.09.2007

2.0

Liliana Soare

23.05.2008

3.0

Liliana Soare

20.09.2008

4.0

Liliana Soare

8.10.2008

5.0
6.0
7.0

Liliana Soare
Liliana Soare
Liliana Soare

15.05.2009
22.10.2009
1.03.2010

8.0

Liliana Soare

28.09.2010

9.0

Liliana Soare

22.03.2011

10.0

Liliana Soare
Manuela
Nastasia

1.09.2011

11.0
12.0
13.0
14.0
15.0
16.0
16.0
17.0

Manuela
Nastasia
Manuela
Nastasia
Manuela
Nastasia
Manuela
Nastasia
Manuela
Nastasia
Manuela
Nastasia
Manuela
Nastasia

24.01.2013

Description of Version
Main or important changes since previous version
Writing the manual
Up-date the manual with plant descritption, list of
by-products, new investments in 2008; up-date
management team; up-date HACCP team; up-date
risk analysis overview for new bottling line; up-date
CCP summary with bottle burst system, up-date
CCP 6 and those for new bottling line
Up-date flow chart of Becks Green Lemon
Update flow chart with Prephop installation,
Brewhouse Line 2 , Kieselghur option on Filtrox
installation, up-date management team, up-date
hazard analysis on Brewhouse Line 2, up-date CCP
2 and Kieselghur option
Update new investments for 2009, update
management team, update flowcharts according
with new changes
Update management team
Update plant history, management team, new logo
Revise codification for critical control points, update
the related CCP summary & flow charts
Update management team
Update with BB Fresh, BB Nefiltrata, Staropramen
and risk analysis for BB Fresh process

14.03.2014

Update with BB Fresh Grapefruit

Update with new beer and syrup installation for BB
Fresh Grapefruit and BB fresh Lemon production,
update management team
Update management team , Update with BB Fresh
Grapefruit NA production

20.05.2014

Update management team

19.09.2014

Update management team

Include in the HACCP Manual the list of raw
materials and materials and origin of ingredients
Include in the HACCP Manual the list of raw
materials and materials and origin of ingredients
Change the document number according to new
requirements

10.04.2013

17.10.2014
17.10.2014
13.04.2015