(Module 3: Health, Safety, Environment and Food Safety)
Module 1 – Raw Materials
Barley:
– Malting barley varieties
– National approved barley varieties
– Breeding and growing malting barley
– Barley identification, the use of morphological characteristics and electrophoresis
– Non GN varieties
– Diseases and seasonal factors
– Pre-germination
– Basic knowledge of other cereals used for malting
– Basic knowledge of farming practices
– Sustainable/Regenerative farming practices
– Biodiversity
Barley purchasing and handling:
– Barley Contracts
– Acceptance/Rejection of deliveries
– Intake and sampling procedures
– Due diligence monitoring
– Farm assurance schemes, grain passports, approved use of post-harvest pesticides
– Drying, screening and storage of grain
– Types of stores
– Conveying and handling equipment
– Infestation precautions and treatments
– Temperature control and monitoring of stored grain
– Maintaining quality prior to malting
Principles and interpretation of barley analyses:
– Controls for reducing the impact of dormancy
– Germinative energy and water sensitivity tests
– Water uptake assessments
– Micromalting tests
Barley supply and demand:
– political factors affecting world trade in barley
– World grain market drivers – eg biofuels, weather, commodities and geopolitics
Module 2 – Processing
Steeping:
– Water quality and typical volumes used for processing
– Effects of differing water temperatures
– Use and design of aeration equipment and design used in steeping
– Importance and function of air rest periods
– CO2 extraction, equipment design and typical air volumes used in various designs of steeping vessels
– Achieving appropriate levels of moisture during the steeping process and at cast
– Design of steeping equipment
– Barley washers
– Use of automated recipe based process controls
Additives and processing aids:
– Reasons for the use and application of GA
Germination techniques:
– Different types of vessel design
– Control of moisture in germination
– Control of air temperature and the volumes of air used to maintain control
– Batch size
– Humidity control equipment
– Visual evaluation of germinating grain
– Use of automated recipe-based process controls
– Endosperm modification, enzymes, cell wall modification and proteolysis
Psychrometric charts:
– Interpretation and use in designing a malting plant
Kilning procedures:
– Variations for different malt qualities
– Fuels and heating equipment used for kilning
– Kiln design
– Methods in use for reducing energy consumption
– Control of malt analysis
– Malting loss management by variation in processing techniques
– Coloured/roasted and special malts including peating, DMS malt adn High DP/DU products
– Control of flavour compounds in kilning
– Use of automated recipe-based process controls
– Control of NDMA
Types of malting plant:
– Machinery and conveyors
– Air conditioning systems
Malt Despatch:
– Deculming
– Screening
– Weighing
– Sampling
– Grading
– Storage and stock control
– Despatch in bags and bulk
– Conveying equipment to minimise malt breakage
– Malting loss, its source and control
Recommended methods of malt analyses:
– IOB, EBC, ASBC Methodologies
– Specification
– Interpretation
– Quality assurance and quality control
– Use of statistical techniques
– Repeatability and reproducibility
Co-products :
– Production and handling
– Analysis
Distribution:
– Bulk vehicles
– Sacked malt distribution
– Containerised Export including customs/SOLAS considerations
General understanding of the brewing and distilling processes:
– Reasons for specifications of certain malt properties
– Diastatic and non-diastatic malt extracts
– Glycosidic nitrile (GN)
– Predicted spirit yield (PSY)
– The influence of malt quality on brewhouse/distilling performance
– Mashing and separation techniques
– Wort quality
– Uses of malt and malt products within the food industry
International malting industry and its markets:
– Industry economics
– Producers and users
– Political factors (eg CAP, WTO) affecting world trade in malt
Module 3 – Health, Safety, Environment and Food Safety
Hazards and safety in malting:
– Health and safety issues
– Confined spaces
– Dust and explosion risk and DSEAR regulations
– Safe working procedures
– COSHH
– Work permits
– Risk assessments
– Handling and storing chemicals and additives
Accident reporting:
– RIDDOR
Standards and Legislation:
– ISO 9001, ISO 14001, ISO 45001, ISO22000, ISO50001
– FSSC
– BRC
– Farm to Fork
– FEMAS
– UFAS
– TASCC
– GTAS
– AUKM
– Organic, Kosher and Halal Certification
– HACCP
– TACCP
– VACCP
– The Food Safety Act
– Feed Hygiene Regulations
– Food Hygiene Regulations
– DEFRA Code of Practice for the Control of Salmonella
– Health and Safety Legislation
– IPPC
– EU Food Safety Directives and Legislation
– PUWER
– CDM
– Control of Noise Regulations
Environment & Climate Change:
– Sustainability
– Carbon footpint
– Type 1,2 & 3 emissions
– Net zero
– Construction of a risk matrix for environment
– Organising mitigation measures
– Environmental impact of different parts of the process
– Waste management
– Environment Agency (EA) Permits
Quality:
– Quality assurance schemes
– Reporting, monitoring and controlling quality
– Impact on business operations and on malt performance in the brewery or distillery
– Analytical parameters
– Typical values
– Action measures when outside pre-defined limits
– Proficiency testing schemes
Food Safety:
– Cleaning and plant hygiene
– Magnets
– Awareness of certification standards
– Legionella
– Pest control
– Integrated Pest Management
– Microbiological testing
Malting Engineering:
– Fan laws and their interpretation
– Principals of heat transfer – conduction, convection and radiation
– Fluid flow: definition of laminar and turbulent flow, calculations on volume flow, Bernoulli equation
– Valves – types and applications
– Electrical motors
– Pumps: types and applications
– Materials of Construction- Stainless steel types, mild steel use, corrosion, insulation
– Asset Management
– Preventative Management System
Energy Efficiency
– Energy efficient motors
– Inverter drives
– Electricity: all aspects of supply and distribution
– Fuel types, costs pros and cons
– Low Carbon fuel alternatives
– Renewable Energy
Energy conservation:
– Maintenance – computerised maintenance management systems, costs, compliance checks
– Instrumentation automation, PLC controls
– Control systems, closed loop, open loop
Services:
– Water
Waste water:
– Principles of treatment
– Water re-use