EDUCATION

SAMPLING SOPs

Sterilizing Valves

Samples throughout a craft beverage facility are regularly taken via a sample valve or zwickel.

Valves of this type can be of various designs, but the most important thing to ensure, at least from a quality testing perspective, is that they can easily be cleaned, sanitized, and fully sterilized.

For that reason, threaded valve connections should be avoided whenever possible since it is much more difficult, if not impossible, to sterilize hard-to-clean thread surfaces under normal operating conditions.

Sample valves are either clamped directly to a tank, length of flanged process piping, or to a butterfly valve.

Each of these scenarios requires a slightly different set of steps to achieve sterile conditions.

EQUIPMENT*

Needed to Perform SOP

70% isopropyl alcohol in spray or wash bottle
sterile swab or nylon brush
butane torch
sterile container to capture sample (ex. Whirl-Pak)
waste container
silicone gasket
stainless clamp

If also cleaning butterfly valve:

soft scrub pad
alkaline cleaning solution
sanitizing solution
stainless steel forceps
stainless steel 90-degree fitting

*Consult lab equipment list

For Other Pieces of Equipment Employing Samples Valves

> Centrifuge

> Filter

> Heat Exchanger

> Pasteurizer

Use the appropriate method described below.

Scenario 1

When clamped directly to a tank or pipe containing liquid, a gasket bridges the gap between flanges and prevents leaks. In these cases, it is necessary to sterilize the sample valve in place following the series of steps below.

STEP 1

Prep the Sample Valve

-Spray both the inside and the outside of the valve outlet with 70% isopropyl alcohol

-Submerge either a sterile swab or nylon pipe brush in 70% isopropyl alcohol and scrub the inner surface of the valve outlet to loosen or dislodge any dried material

-Flame the valve for a short time only and allow to extinguish. Continuing to apply heat may damage the metal or gasket and/or cause liquid inside the flange to bake onto the metal.

-Allow the valve to cool

-Spray 70% isopropyl alcohol on both the inside and outside of the valve outlet

-Flame the valve again

-Allow it to cool

STEP 2

Clear the Sample Valve

-With a waste container positioned below the valve outlet, open the valve all the way and allow product to flow out for 5-10 seconds.

-Close the valve, being careful not to touch it, and put the waste container aside

Collect the Sterile Sample

-Pick up the container in which the sterile sample will be collected

-Carefully remove the lid or spread its top open and place below the valve outlet

-Open the valve and collect the sterile sample, being careful not to touch the valve with the container

-Close the valve

-Close or re-seal the sterile sample container and set it aside

-Spray the sample valve inside and out again with 70% isopropyl alcohol, flushing out all liquid

-Flame the valve one last time

OTHER SAMPLING SOPs

> Bottles & Cans

> Butterfly Valve

> SAMPLE VALVE

* Sampling SOPs Coming Soon…

> Draft Faucet

> Keg Coupler

> Wooden Barrel

SAMPLING PLAN

-A SAMPLING PLAN can be a helpful tool when determining, based upon the size of an operation and the various pieces of equipment installed, which samples to gather, how often, and the particular FastOrange media recommended for testing.

Scenario 2

If the sample valve is clamped to a butterfly valve that is already clamped to a tank or pipe flange, it is necessary to first clean and sanitize the valve before it is sterilized.

STEP 1

Prep the Butterfly Valve

-Rinse the face of the butterfly valve with water

-Clean the face of the butterfly valve flange, the length of tubing behind the flange, and the flexible seating material with the standard concentration of alkaline cleaner and either a scrub pad or nylon brush

-Rinse the clean area with water

-Clamp a clean 90-degree stainless elbow onto the butterfly valve flange, facing the open end upward

-Fill the elbow with the standard concentration of sanitizing solution and allow to soak.

STEP 2

Prep the Sample Valve

-Soak a clean sample valve in the standard concentration of alkaline cleaner, leaving the valve open and disassembled so the cleaning chemical touches all internal surfaces

-Remove the valve from the cleaning solution and rinse with water

-Place the valve in the standard concentration of sanitizing solution and allow to soak.

Prep the Silicone Gasket

-Soak a clean silicone gasket in jar of 70% isopropyl alcohol

-Remove gasket from jar using clean stainless steel forceps, making sure the tip of the forceps is covered in alcohol too

-Holding the forceps a safe distance away, ignite the alcohol-covered gasket and, without applying additional heat, allow flame to extinguish on its own.

STEP 3

Flame the Butterfly Valve

-Unclamp the 90-degree elbow from the butterfly valve and drain sanitizer

-Spray butterfly valve with 70% isopropyl alcohol, making sure to contact the flange, the length of tubing behind the flange, and the flexible seating material

– Flame the valve for a short time only and allow to extinguish. Continuing to apply heat may damage the metal, gasket, and/or cause liquid inside to bake onto the metal.

-Allow the valve to cool

STEP 4

Flame the Sample Valve

-Remove the sample valve from the sanitizing solution and rinse

-Spray 70% isopropyl alcohol on the valve flange

-Flame the valve flange

-Allow the valve to cool

-Clamp the sample valve to the butterfly valve using a clean and sanitized gasket

-Spray both inside and outside the valve outlet with 70% isopropyl alcohol

-Flame the valve outlet

-Allow it to cool

-Close the sample valve and open the butterfly valve

-With a waste container positioned below the valve outlet, open the sample valve all the way and allow product to flow out for 5-10 seconds

-Close the sample valve, being careful not to touch it, and put the waste container aside.

STEP 5

Collect the Sterile Sample

-Pick up the container in which the sterile sample will be collected

-Carefully remove the lid or spread its top open and place below the sample valve outlet

-Open the valve and collect the sterile sample by running liquid into the sterile container, being careful not to touch the valve with the container

-Close the sample valve

-Close or reseal the sterile sample container and set it aside

-Close the butterfly valve

-Unclamp the sample valve from the butterfly valve, open the sample valve, and rinse

-Soak the sample valve in the standard concentration of alkaline cleaner

-Rinse the face of the butterfly valve with water

-Clean the butterfly valve with the standard concentration of alkaline cleaner, using a scrub pad or nylon brush

-Rinse the butterfly valve with water

-Splash or spray the butterfly valve with the standard concentration of sanitizing solution

-Cap the butterfly valve

-Rinse the sample valve with water

ALTERNATIVELY

Autoclave the Sample Valve

-If the sample valve can be sterilized in an autoclave, proceed to step 4, where the sample valve is clamped to the sterile butterfly valve after it is flamed.