Professional Documents
Culture Documents
Date 15
19%
Open
Closed
Overdue
Due
53% Today 43
23% 19
Total Gaps : 81
Gap Area Action (Source: GSC Audit)
No.
RAW MATERIAL
1 Processes 3 Malt silos and 1 rice silo not
commission yet
WORT HANDLING
21 Processes Oxygen level reported to 16 ppm.
Measured by a portable O2 meter
straight after the aeration.
Distance to from BH to fermenters
short.
22 Processes All wort streams are cooled 1 0C
below fermentation temperature
PROPAGATION/YEAST HANDLING
25 Processes Propagation done according to
logarithmic phase. Propagation in
Carlsberg Flask not according to
good micro practice. Broken gasket
on the C-flask
FERMENTATION
31 Processes Performance of Carlsberg yeast 234
observed poor. Slow Diacetyl
reduction and yeast sedimentation
32 Processes 140 yeast showed long Diacetyl rest
time
FILTRATION
36 Processes There is no quality check at the start
up of filtration
PACKAGING, BOTTLING
42 Empty bottle Empty bottle storage, handling and
handling sorting is a major issue at the
brewery. ….And well known to the
brewery management.
Further to this it is not allowed using
Kingfisher embossed bottles for local
product causing extra sorting.
· Maintenance of bottlewasher
WAREHOUSING
55 Processes Lots of expired product found
segregated in the warehouse
awaiting tax clearance before
dumping.
55 Processes Lots of expired product found
segregated in the warehouse
awaiting tax clearance before
dumping.
UTILITY
58 Processes · CO2 collection starts 24 hours
after tank full.
· CO2 purity not informed
· Strong off flavour of cooked
tomato in Monday CO2 taste sample
QUALITY MANAGEMENT
64 Sampling Plan Good knowledge of sampling plan –
however many printed versions of
the sampling plan exists.
Analyses Diacetyl measurements were gone
through and the following was
observed risking incorrect results.
15
43
19
Reccomendations Status
Once commission, secure malt traceability and We get imported barley malt from one batch for
introduce silo program – batch separation. one full silo. For Indian malt and rice we will get
bulk load from one batch only and will not top
up with another batch till the first one finish.
Malt specification as per the COM must be Approved variety rley specified in COM is
followed. Analytical report to include all specific purchased and converted in India. We will
parameters. (Barley is purchased from ensure parameters are as per COM.
Carlsberg approved supplier).
Malting plant needs to be audited ASAP Barmalt audit scheduled dates were
communicated to Chonlada for reaudit.
Rice sample must be analyzed as per We are in process of buying sifter for analysing
specification in the COM especially when using grain size as per COM. Other chemical analysis
high rice content as adjunct. Physical analysis will be done in lab as per sampling plan in COM
such as impurities are of course checked at the CD.
brewery.
Milling setting to be checked and lowered if After the installation of new fluted rollers and
necessary. Also enzyme dosing to be adjusting the mill settings saccharification times
investigated. will be improved
Consider installation of weighers in order to Invited quotations from Krones and Buhler.
control material usage and brewhouse
performance.
Technical engineering standard – execution to Discussing with supplier to close the gaps
be discussed with supplier before contract
closure.
Evaluation of the current mashing profile - This issue is due to the new crop of local barley
and poor dormancy period.In Sep things with
the improved malt we will fine tune the mashing
profile
1. The load cell could be used for in house Installing batch weighing system on both rice
brewhouse yield calculation. Loading cells do and malt silos as recommended.
not work properly due to vibrations and solution
is being discussed with Krones.
2. The validation of total weigh from sack
should be done: once a month.
1. The master list of calibration should be 1. Attached herewith the master calibration list.
available for B&P as well. 2. Temperature set to get the required set
2. Ensure the achievement of set point in every point in mashing diagram.
brew.
1. Trouble shooting should be done when we Higher sachrification time is largely due to poor
have long sachairifation time. For example:- malt quality. However, we have started
check the gap roller, malt quality, enzymes analysing other parameters on case to case
adding, etc. basis for high sachrification time.
1. Addition of water at LT could be reduced to Flushing 8 Hl water is for cleaning the LT and
improve the first wort gravity (currently before under let it is draining. So actual qty is
average gravity is 20.6%P) only 5 Hl.We will monitor the first wort gravity
vs last run gravity with the reduced water
Reduce extract in last runnings – Improving BH volumes
yield.
1. Brewhouse yield, hop utilisation and 1. Implemented (Refer the attached format).
evaporation rate should be calculated and 2. Here attached the revised calculation
record into the logging book considering RDF and total loss.
2. Cost comparison of 50:50 and 60:40 will be
calculated. RDF and total loss must be taken
into consideration
· Hop addition could be standardized by Hopping dosages are done based on the types
taking Hop utilisation monitoring into of hops available in stock as per contract done
consideration by group supply chain .The first sample already
Hop pallet should be sent for yearly analysis at dispacthed on 13th Aug 2010
TC
1. Zinc and calcium to be measured on yearly Will check both Zinc and calcium from reputed
basis. lab outside. Wort sample sent to France on 13th
2. Wort sample to be sent to TC, France Aug 2010.
Brewhouse yield to be calculated to identify It is done on daily and monthly basis. Atached
losses and to control brewhouse performance BH logsheet for reference.
and material usage.
1. Check the maintenance plan requirement in Invited quotation for refluting. We will get it
the machine manual done during next shutdown.
2. Prepare the spare part, re-flute of miller
1.Test was done during the audit by transfer We are in process of installing static
first brew to a fermenter without yeast and mixer( ventury system) in wort cooling which
measured ;- result was 10.6ppm) was discussed during this observation.Taken up
2. Further investigation for a static mixer or with Krones
similar system due to the short distance from
BH to fermenters
Cooling set point could be the same as the Implemented
fermentation temperature. Cost saving.
This is an overall impression throughout the Krones engineer already visited the site. Will
brewing and processing area. Some photos take handover after completion of work and
attached. closing gaps
Propagation in Carlsberg flask trained during Will follow the procedures as per the training
audit to ensure sterility. Purchase new spare given. Spares under procurement process.
parts from Alfa Laval
If the yeast is free of contamination and viable As discussed with Briggit According to the
it can be used up to 10 generations. – reducing Viablity we are going to use up to 10 th Gen
losses as yeast is just drained.
Go through plant and update accordingly - Special care is now taken to clean dead end
wherever elimination is not possible.
Please refer photograph of welding joints
finished after audit.
Sterilisation procedure of sample cork attached
for reference.
To be discussed with supplier. (photo attached). Krones engineer already visited the site. Will
take handover after completion of work and
closing gaps
Reduce CIP temperature to be max 80 to 82 0C Implemented (Attached revised SOP for
on return. Longer lifetime on gaskets etc. reference)
· Reduce CIP times, caustic contraction and We have reduced as recommended and trials
water flushes. under observation.Will evaluate the results and
· Reduce caustic circulation as well as water continue if satisfactory
flushing
· Ensure that the Operator is aware of KSG Plan is to shift one control PC on ground floor in
availability during filtration filtration area for better control with the
operator.
· Filtration logging sheet should be done at
the filter
The audit team cannot give any We are working on the issue to get the best
recommendations as this is a "local" problem – solution
and looked after by the local management
team.
It could be recommended investigating in pre- We are installing showers at in feed bottles. The
cleaning of bottles either by installing shower work is in progress.
heads before the bottlewasher – (reusing water
from the filler vacuum pump – or soaking
bottles in water before conveying to the
bottlewasher (Info from Chonlada)
Start using biocides to avoid micro growth in Thermax and Johnson Diversy are coming for
the pasteuriser. Reducing water consumptions analysis and proposal.
as pasteuriser water does not need to be
dumped frequently.
Carton maker broken and awaiting spareparts. Carton erecting machine is under maintenance
and claim amount under insurance.
Conveyor lubrication to be improved. Reviewing lubrication flow quality and quantity.
(Johnson/Diversey).
This will also give longer lifetime of conveyors
and dead plates.
Procedure to be corrected – should not be Safety interlock will be redone
possible due to safety reasons.
Label room to be rebuilt or label storage to be As an interim arrangement, exhaust fan
more to suitable room due to very high provided for cross ventilation (photograph
humidity. attached for reference).
No acid cleaning is included in the CIP Acid cleaning(2 % HNO3) will be done once a
programme. month.
Maintenance plan was demonstrated and it was One set of maintenance finished in 1st week of
informed the yearly overhaul is scheduled after Sep 10. Awaiting internal line audit report from
the peak season. KHS for further action.
It is however recommendable changing the to
be before peak season.
Improve production planning if possible. Discuss Clearing of this stock is under process.
shelf life of product.
Improve production planning if possible. Discuss Clearing of this stock is under process.
shelf life of product.
Repackaging in case of damaged cartons Will be done on daily basis based on the
necessary. condition of the pallet in ware house and also
before dispatching
CO2 purity to be Though the brewery is self CO2 purity check procedure reviewed and
sufficient with CO2 it is recommendable to changed. Attached testing report for reference.
investigate in starting recovery of CO2 earlier.
Normal procedure in other breweries is approx.
16 hours after start filling of fermenter.
· The auditors understood that this is Have submitted protest letter to state electricity
something the brewery just live with. Can board earlier. Also, meeting held with
something be done? Superitendent Engineer on 19th Aug 10 to
· Generator working very frequently. Some discuss the same matter. He has assured for
months with high fuel consumption affecting the improvement.
energy KPI's negatively.
· Many issues with the candle filter as this is
very sensitive to pressure drops.
Could affect ownership of equipment. It was
understood that the management at the
brewery is looking into including these
operations in the brewery again.
Only the latest update of the sampling plan Done. Obsolete old sampling plan copies and
from GSC must be in place. As on date updated sampling plan with
reference to COM is in place
· In general the team understand how to Now the online lab is being shifted to 1st floor
measure oxygen and follows the plan but · and is closed room. All the parameters including
To be analysed immediately after start up sensory has been started. Attached herewith
the logsheet for reference.
Carlsberg India registered as one "unit only" From 2011 brewery Alwar will be participating
Alwar will from next year reported separately individually. As on date, samples and results are
for BAPS, MICRO and Flavour Active. Could be submitted in brewery 320 code.
started immediately.
It is noted that the Alwar brewery has had a
flavour active taste course.
Include a standard reference beer in
It is recommended changing to the scoring As per latest COM CD, the format is +1 tp -3
system from 1 to 9 which is the system in use which we are using.
at Carlsberg.
Stop analysis as infection problems should have Will follow immediately the unpasteurised beer
been found before. Micro checks only done micro plating
when unpasteurised beer has been packaged.
Include a steam sterilizer in the quality budget. Gas burner for sterilization process in place.
However, initiated the process to purchase the
steam sterilizer.
To be used for identification of colonies. Implemented. Attached scan copy of log sheet
for reference.
Training in micro trouble shooting should be Training is planned in 4th QTR 2010.
part of future training plan. Time constrains
during the audit did not allow for this training.
Actionlog ALWAR : 2-5 August 2010
Date
8/5/2010
11/5/2010
Anand Manufacturing
Kalwaghe/Manish
Garg
Gopal Krishnan Central Technical
Asheesh Agarwal
Quality Assurance Quality Assurance
RH/MG Technical
Asheesh Agarwal QA
3
Deadline Fixed date Status
30-Sep-10
OVERDUE
30-Aug-10 30-Aug-10
CLOSED
15-Oct-10
OVERDUE
30-Sep-10
OVERDUE
15-Nov-10
OPEN
15-Sep-10
OPEN
15-Sep-10
OPEN
30-Sep-10
OVERDUE
31-Mar-11
OPEN
30-Nov-10
OPEN
30-Sep-10 30-Aug-10
CLOSED
30-Sep-10 30-Aug-10
CLOSED
30-Sep-10
OVERDUE
31-Aug-10
OVERDUE
30-Sep-10
OVERDUE
30-Sep-10
OVERDUE
31-Aug-10 10-Aug-10
CLOSED
30-Nov-10
OPEN
31-Aug-10
OVERDUE
15-Sep-10
OVERDUE
30-Nov-10
OPEN
31-Aug-10 30-Aug-10
CLOSED
30-Sep-10
OVERDUE
NO DUE DATE
30-Sep-10
OVERDUE
31-Aug-10 30-Aug-10
CLOSED
31-Aug-10 25-Aug-10
CLOSED
15-Sep-10
OVERDUE
15-Sep-10
OVERDUE
31-Aug-10 30-Aug-10
CLOSED
30-Aug-10 30-Aug-10
30-Aug-10 30-Aug-10
15-Sep-10
CLOSED
15-Sep-10
CLOSED
15-Sep-10
OVERDUE
31-Jan-11
OPEN
30-Sep-10
OVERDUE
15-Sep-10
OVERDUE
31-Aug-10
OVERDUE
31-Jan-11
OPEN
31-Aug-10 30-Aug-10
CLOSED
30-Sep-10
OVERDUE
31-Dec-10
OPEN
31-Aug-10
OVERDUE
30-Oct-10
OVERDUE
30-Nov-10
OPEN
30-Oct-10
OVERDUE
5-Nov-10
DUE TODAY
31-Aug-10 30-Aug-10
CLOSED
30-Sep-10
OVERDUE
10-Sep-10
OVERDUE
30-Sep-10
OVERDUE
10-Sep-10
OVERDUE
5-Sep-10 5-Sep-10
CLOSED
27-Aug-10 27-Aug-10
CLOSED
15-Sep-10
OVERDUE
15-Oct-10
OVERDUE
NO DUE DATE
NO DUE DATE
31-Aug-10 10-Aug-10
CLOSED
30-Sep-10
OVERDUE
15-Sep-10
OVERDUE
30-Aug-10 8/10/10
CLOSED
30-Sep-10
OVERDUE
9-Sep-10
OVERDUE
30-Sep-10 OVERDUE
30-Sep-10
OVERDUE
30-Sep-10
OVERDUE
30-Aug-10 10-Aug-10
CLOSED
30-Aug-10 10-Aug-10
CLOSED
30-Aug-10 30-Aug-10
CLOSED
15-Sep-10 OVERDUE
30-Sep-10
OVERDUE
30-Sep-10
OVERDUE
31-Mar-11
OPEN
31-Mar-11
OPEN
31-Mar-11
OPEN
30-Sep-10
OVERDUE
30-Aug-10 30-Aug-10
CLOSED
1-Apr-11
OPEN
NO DUE DATE
30-Sep-10
OVERDUE
30-Sep-10
OVERDUE
30-Sep-10
OVERDUE
30-Sep-10
OVERDUE
30-Oct-10
OVERDUE
Closed
15 19 43
Remarks
1