SAQA All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.
SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD THAT HAS PASSED THE END DATE: 

Optimise the cleaning and sanitising of a beer manufacturing environment 
SAQA US ID UNIT STANDARD TITLE
119284  Optimise the cleaning and sanitising of a beer manufacturing environment 
ORIGINATOR
SGB Food 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-  
FIELD SUBFIELD
Field 06 - Manufacturing, Engineering and Technology Manufacturing and Assembly 
ABET BAND UNIT STANDARD TYPE PRE-2009 NQF LEVEL NQF LEVEL CREDITS
Undefined  Regular  Level 6  Level TBA: Pre-2009 was L6  10 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Passed the End Date -
Status was "Reregistered" 		 2018-07-01  2023-06-30  SAQA 06120/18 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2024-06-30   2027-06-30  

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.  

This unit standard does not replace any other unit standard and is not replaced by any other unit standard. 

PURPOSE OF THE UNIT STANDARD 
A person credited with this unit standard is able to:
  • Manage and control the cleaning process
  • Measure and analyse the effectiveness of the cleaning process.
  • Identify non-conformance of the cleaning process
  • Manage and implement corrective action

    This unit standard is intended for practicing brewers who need to understand and apply cleaning and sanitising principles to the maintenance of an appropriate level of hygiene within the brewing processing plant thereby preventing contamination and spoilage of final product and brewing products in process.

    The skills, knowledge and understanding demonstrated within this unit standard are essential for social and economic transformation and upliftment for any individual. 
    		•

    LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    Chemistry
  • Caustic cleaning fluids
  • Acid cleaning fluids
  • Neutral cleaning fluids
  • Reactions of carbon dioxide with cleaning agents
  • Sanitizers and their modes of action
    Microbiology
  • Basic concepts of inhibition and elimination of contaminants
    Engineering
  • Knowledge of materials of construction
    > Types of stainless steels
    > Hygienic design principles
    Brewing process
    > Desired levels of hygiene for each aspect
    Basic Problem Solving Techniques
    World Class Manufacturing 
    		•

    UNIT STANDARD RANGE 
    This unit standard range is applicable to the management and control of brewery plant and process hygiene from raw material acceptance to release of final product. 

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Manage and control the cleaning process. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The appropriate detergents and sanitisers used for cleaning are selected to obtain the required level of hygiene on all equipment used for the manufacture of beer. 
    ASSESSMENT CRITERION RANGE 
    The factors include:

    Cleaning Systems:
  • Cleaning In Place (can be automated or manual)
  • Manual

    Detergents
  • Formulated detergents that are alkali or acidic based.
  • Surface-active compounds as wetting agents.
  • Chelating agents or sequestrants.
  • Flocculating agents.

    Sanitisers
  • Sanitisers for non-rinse applications.
  • Sanitises that require rinsing
  • Sanitiser baths.
  • Environmental sanitisers.
  • Steam.

    Hot applications on vessels
  • Typical process operation
    > Rinse water to eliminate excess soil.
    > Alkali detergent at specific concentration and at high temperature for specific time.
    > Rinse water to clear alkali residue.

    Cold applications (process vessels with CO2)
  • Typical process operation
    > Flush out CO2 from vessel with water.
    > Circulate alkali detergent at specific concentration in burst for specific time.
    > Rinse.
    > Circulate acid detergent at specific concentration for specific time.
    > Rinse
    > Circulate sanitiser at specific concentration for specific time.
    > Rinse with water for specific time.

    Pipe lines, fillers - hot application
  • Typical process operation
    > Flush with water and circulate back to surplus water tanks.
    > Circulate alkali detergent at specific concentration at high temperature for specific time.
    > Rinse
    > Circulate sanitiser at specific concentration for specific time.
    > Rinse with water for specific time.

    Other materials
  • Use of detergents and sanitizers on aluminum kegs and vessels.
  • Use of detergents and sanitizers for filters.
  • Use of detergents and sanitizers on hosepipes.
  • Use of detergents and sanitizers on copper vessels and piping
  • Use of detergents and sanitizers on beer dispense systems
     
    		•

    ASSESSMENT CRITERION 2 
    The cleaning and sanitizing programmes are designed and managed to eliminate specific soil loads on the surface of the relevant equipment. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Soil loads are determined by the composition of the materials used in the process, the process conditions in terms of temperature and time and the design of the equipment.
    > Detergent concentration
    > Mechanical action
    > Temperature of cleaning
    > Time used for cleaning
    > Proteins.
    > Carbohydrates.
    > Fats and oils.
    > Cellulose husk material.
    > Inorganic salts from water and cleaning agents.
    > Biofilms.
    > Temperatures of between -1 to 130°C that impact on the attachment of soil to the surface.
    > Surfaces that are difficult to access during manual or cleaning-in-place regimes.
     
    		•

    ASSESSMENT CRITERION 3 
    The physical characteristics that determine the hygienic nature of materials of construction (vessels and pipes) are identified and applied to the different equipment used to manufacture beer. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Equipment used in the handling and storage of all raw materials used in the brewing process including barley and sorghum malt; liquid sugars; maize grits and starch; hop extract and pellets; and water at ambient temperature, cold water (1 to 10°C) and hot water (40 to 95°C).
  • Equipment used in the storage of cleaning and sanitizing agents as received from the suppliers.
  • Equipment used in the entire processing of beer including milling plant, brewhouse plant, yeast processing, fermentation and maturation vessels, clarification plant, filtered beer vessels all with associated piping, hoses, valves, heat exchangers, agitators and measuring instruments.
  • Equipment used in the storage of Cleaning-In-Place solutions and sterilants bathes used in all the brewing and packaging processes.
  • Equipment used in the packaging process of beer in glass and PET bottles, cans and kegs, including fillers and related pipelines.
  • Joints and seals (elastomers) used as part of all relevant equipment.
     
    		•

    ASSESSMENT CRITERION 4 
    Cleaning programmes for vessels are determined by the soil on the surface, the stage of the process (hot or cold) and the geometry and attachments in the vessel. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Detergent concentration
  • Mechanical action
  • Temperature of cleaning
  • Time used for cleaning
  • Composition and thickness of soil.
  • Extent of soil over the surface of the vessel.
  • Geometry
  • Internal attachments that create shadows where cleaning agents have not impacted on the surface. (Mechanical impact of cleaning agents and its positive effect on the efficiency of the cleaning regime)
  • Heating surfaces where soil burns on.
  • Heating or cooling surface on the vessel that allows for "hot" or "cold" cleaning regimes.
  • Safety Operating Procedures
     
    		•

    ASSESSMENT CRITERION 5 
    Cleaning and sanitizing programmes for pipe work and related in-line pumps, valves, instruments, heat exchangers, hoses and other items (e.g. fillers) are determined by the soil on the surface, the stage of the process (hot or cold) and the design of all the items of plant in the cleaning circuit. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
    Soil
  • Composition and thickness of soil.
  • Extent of soil over the surface of the item of plant.
    Geometry and attachments
  • Internal attachments that create shadows where cleaning agents have not impacted on the surface.
  • Heating surfaces where soil burns on.
  • Heating or cooling surface on the vessel that allows for "hot" or "cold" cleaning regimes.
    Safety Operating Procedures
  • Strictly complying with company safety operating procedures when cleaning equipment.
     
    		•

    ASSESSMENT CRITERION 6 
    The cleaning cycle plan is produced to meet customer's requirements. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Process area availability
  • Cleaning and sanitizing time
  • Maintenance time
  • Safety precautions
  • Cleaning plant availability
  • Downstream factors
     
    		•

    ASSESSMENT CRITERION 7 
    The cleaning cycle plan is communicated and accepted by all relevant parties. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Internal customers
  • External customers
  • Labour requirements
     
    		•

    ASSESSMENT CRITERION 8 
    The daily cleaning and sanitizing activities are managed according to plan. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Actual vs. plan
  • Costs
  • Human resources
  • Safety
  • Storage
  • Effluent control
  • Communication of revisions
  • Records and documentation of completed cleaning programmes updated
    > Operator records
    > System records
     
    		•

    ASSESSMENT CRITERION 9 
    The required legislative standards are applied managed and controlled. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • HACCP
  • Occupational Health and Safety
  • ISO 14000
  • ISO 9002
     
    		•

    ASSESSMENT CRITERION 10 
    The hygienic status and performance of the plant is recorded. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Quality systems
  • Documentation
     
    		•

    ASSESSMENT CRITERION 11 
    The principles of world-class manufacturing are applied to optimize the cleaning process. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Knowledge of world class manufacturing principles
     
    		•

    SPECIFIC OUTCOME 2 
    Measure and analyse the effectiveness of the cleaning process. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Quality assurance parameters for the cleaning and sanitising programmes are monitored and controlled according to standard operating procedures. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Temperature of water, cleaning and sanitising agents,
  • Concentration and pH of cleaning and sanitising agents,
  • Programme sequence and duration of different steps (contact time),
  • Flow rates.
     
    		•

    ASSESSMENT CRITERION 2 
    The surfaces post cleaning are inspected to detect residual surface contamination using approved methods. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Visual inspection
  • Rinse sampling.
  • Swab sampling.
  • Media plating applications.
  • Forcing tests.
  • Bioluminescence testing.
     
    		•

    ASSESSMENT CRITERION 3 
    The surfaces post cleaning are inspected to detect deterioration that would negatively impact on plant hygiene and integrity. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Non-destructive sampling of the surface: surface roughness measurement.
  • Replicating sample of the surface for further microscopic examination.
  • Dye penetrant testing of cracks or pin holes.
     
    		•

    ASSESSMENT CRITERION 4 
    The concentration of the cleaning and sanitising agents are determined according to standard chemical principles. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Sampling
  • Analytical techniques
  • Microbiological techniques
  • Legal requirements
    > HACCP
    > ISO 9000
     
    		•

    SPECIFIC OUTCOME 3 
    Identify non-conformance of the cleaning process. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The composition and surface finishes that impact negatively on the hygienic nature of the equipment surfaces in direct contact with product are identified. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Process equipment made from stainless steel, copper, aluminum, rubber hoses and lined surfaces where temperatures from -2 to + 40°C are applied.
  • Organic and inorganic soil build up on all surfaces of vessels, pipelines, valves, measuring instruments, agitators and heat exchange surfaces.
  • Implications of biofilm build up on surfaces and its effect on the quality of the beer and on corrosion of the surface of the equipment.
  • Implication of delimitation for lined surface of vessels on the required level of hygiene and on the quality of beer.
  • Implication of deterioration of any of the surfaces of the equipment by corrosion or material failure on the required level of hygiene and on the quality of beer.
  • Implication of poor workmanship in the manufacture of equipment on the required level of hygiene and on the quality of beer.
  • Implications of residual soil or cleaning agents left behind after the cleaning regime on the required level of hygiene and on the quality of beer.
     
    		•

    ASSESSMENT CRITERION 2 
    The plant pipework and vessel design is assessed for conformance to engineering hygienic design principles required for the manufacture of beer. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Selection of materials to ensure required levels of hygiene and avoidance of any taint or contamination of the product by the material from the beer process and the cleaning regime.
  • Dimensioning of pipe systems to achieve the required level of hygiene with specific reference to flow rates of the product and cleaning solutions used during cleaning regimes.
  • Supports and anchors on the pipe systems to ensure drainage of pipe systems.
  • Prevention of water hammer in the pipe work during the sequencing of flows of the product and cleaning regimes
  • Selection of pumps to achieve the designed flow rates and required levels of hygiene.
  • Selection of valves to ensure correct flows and required levels of hygiene
  • Selection of fittings that allow for cleaning as part of the manual or Cleaning-In-Place regimes.
  • Selection of pipe work and fittings designs that allow for regular inspection.
  • Selection and appropriate placement of sprayballs and rotating jets.
     
    		•

    ASSESSMENT CRITERION 3 
    The factors that negatively influence the efficiency of a cleaning agent are identified according to standard chemical and hygiene principles. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Contact time between the surface and cleaning agent.
  • Temperature of the cleaning agent.
  • Concentration of the cleaning agent.
  • The extent of the mechanical action applied.
     
    		•

    ASSESSMENT CRITERION 4 
    The presence of non-conformance to standard operating procedures are identified and quantified. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Audit systems
  • Standard operating practices
     
    		•

    SPECIFIC OUTCOME 4 
    Manage and implement corrective action. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    By the use of appropriate problem solving techniques plans to eliminate non-conformance are generated. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Problem solving techniques.
     
    		•

    ASSESSMENT CRITERION 2 
    Implement corrective actions to eliminate identified non-conformances. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Review work practices
  • Modify plant
  • Training and assessment
     
    		•

    ASSESSMENT CRITERION 3 
    The findings are accurately recorded stored and shared. 
    ASSESSMENT CRITERION RANGE 
    The factors include:
  • Knowledge management systems
  • Documentation management system
     
    		•


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
  • Internal moderation.
  • External moderation.
  • An assessor, accredited by the relevant ETQA, will assess the learner's competency.
  • Assessment procedures will be supplied by the ETQA in alignment with NSB requirements.
  • All assessment activities must be fair, so that all candidates have equal opportunities. Activities must be free of gender, ethnic or other bias.
  • Questions and answers to determine theoretical knowledge are expected.
  • Examination of an assessment portfolio.
  • Reporting skills are demonstrated by effective communication, using verbal (language) and/or writing skills.
  • Direct observation in simulated or actual work conditions.
  • Practical demonstration of main activity(s) reflected in the title. 
    		•

    UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
    Embedded knowledge is reflected within the assessment criteria of each specific outcome:
  • Theory of detergency
  • How the cleaning process integrates within the production cycle.
  • Availability and properties of market related cleaning and sanitizing products
  • Compatibility of cleaning materials to product and plant 
    		•

    UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Identify and solve problems in which response displays that responsible decisions, using critical and creative thinking, have been made.
  • Evident in all specific outcomes. 
    		•

    UNIT STANDARD CCFO WORKING 
    Work effectively with others as a member of a team, group, organisation or community.
  • Evident in all specific outcomes. 
    		•

    UNIT STANDARD CCFO ORGANISING 
    Organise and manage oneself and one's activities responsibly and effectively.
  • Evident in all specific outcomes. 
    		•

    UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information.
  • Evident in all specific outcomes. 
    		•

    UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively by using mathematical and/or language skills in the modes of oral and/or written presentations.
  • Evident in all specific outcomes. 
    		•

    UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically, showing responsibility towards the environment and health of others.
  • Evident in all specific outcomes. 
    		•

    UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems by recognising that problem solving contexts do not exist in isolation.
  • Evident in all specific outcomes. 
    		•

    UNIT STANDARD CCFO CONTRIBUTING 
    Contribute to the full personal development of each learner and the social and economic development of the society at large.
  • Evident in all specific outcomes. 
    		•

    UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    REREGISTRATION HISTORY 
    As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015. 

    UNIT STANDARD NOTES 
    N/A 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  49532   National Diploma: Clear Fermented Beverage Processing: Brewing  Level 6  NQF Level 06  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  FOODBEV 


    PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS UNIT STANDARD: 
    This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.
     
    NONE 


    All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.