Beyond Just Bottles

As previously posted, I had a bad score from my Brown Ale at a BJCP home brew competetion that showed signs of infection, and after some research and questions about cleaning and cleaning products, and sanitization, I seemed to be getting some headway... or I thought. I was under the impression that this was a bottle here, and bottle there, and had established what I was going to do to fix it...that was until last night. I opened another Brown Ale to see if it would have issues, and was met with Old Faithful. I grabbed that last 5 bottles and one, after the other, nothing but gushers. Alarmed doesn't begin to describe it; neither does rage, but that wassn't the end of it. I grabbed one of the Ambers that I had made 2 weeks after the Brown, that consequently I had repitched the yeast on. No gushing, but the flavor is lacking all the crystal malt character and it is watery. Open the 90- (repitched the yeast into this as well) from the partigyle I had done: GUSHER! Run to the cellar and grab the Wee Heavy from that same partigyle (which got the same repitch as the 90-): GUSHER! Grabbed the Session Stout with Orange Zest and Cinammon (repitched from 90-): GUSHER! This beer had been entered into the same competion and received remarks about over carbonation and lack of flavor. This beer was also a partigyle with my 10.6% Imperial Stout that also received the same yeast; it is carbing up right now, and have no clue about how far the infection has gotten on it, but over the course of the month it aged on cherries the FG dropped from 1.028 to 10.24. I will be crash cooling this one and drinking quicker than expected.

I thought it was all about the bottles, but with the rapid advance of the infection in all the batches it appears to be the repitching of the yeast. The Brown took 5 months to show signs of infection. The Amber 4.5, and is not fully there yet (only a 6 pack left). The 90- and Wee Heavy 3 months, the Stout, less than 2. I am still going to have to get all new bottling equipment as well since all 5 batches went through it all and I'd rather not risk the infection having taken hold of in my nozzle, tubing, wand, bucket, etc., and end up in my other beers as well. This is causing some paranioa as well; my 8 gallons of ESB had all new yeast, and I under primed due to a mishap with the app I use, and thought it would never carbonate. But now it has a decent amount of carbonation. Could just be the time and temp finally giving it what it needed. Could be the same infection (they have the same "oil slick" on the top of the beer as all these others had, could be residual cleaner, could be infected). I am going to get all the ESB in the fridge and drink quick. I will leave out a few bottles for a couple months and see if they turn into gushers as well just so I can know for sure. If the Saison gets infected, I am not too concerned, but still would like it to stay clean. I also am now concerned about the West Yorkshire and 3726 Farmhouse Ale yeasts I used, since I washed them and kept them, but I used the same mason jar lids w/ rubber seals that I used for storing the 1056 that infected all the others, and I didn't boil my jars or lids, just StarSan.

Time to go back to the basics again. Gonna drain-pour multiple batches this weekend, have to buy new Bottling Bucket, spigot, tubing, wand, and I have an email out to the Mad Fermentationist about the best way to kill any bacteria in my Better Bottles since he moves from wild to clean to wild to clean in his with no ill effects.

Beating the Bottle Bugs

One thing that came of my debacle was a reevaluation of my cleaning and sanitizing procedures. I got a fairly large forum discussion going back and forth over on Tasty Brew. What has seemed to come of it is that my cleaning and sanitizing is fairly tight, but every-so-often I miss a few bottles. This problem could be stemming from micro scratches inside the bottles that are harboring the bacteria that ravage my beer post packaging. I could always throw these bottles away when I end up with a gusher or two. Another option allows me to tighten up my process to have the best beer packaging available.

Cleaning: I told the guys at the LHBS that I wash with Sun Oxygen Cleaner and they stated that this was bad. They told me that it had detergents in it that would coat the walls of my equipment and bottles, that it was difficult to wash off, and that it would de-activate StarSan. I started the forum thread and did some reading and snooping. According to John Palmer, a very good cleaner for your brewery is a Sodium Percarbonate cleaner like PBW and One-Step. Turns out that the Sun Oxygen Cleaner that I use is simply Sodium Percarbonate, just like the expensive stuff they were trying to sell me. According to the forum thread, I wasn't rinsing them well enough, and the Sun MSDS sheet does state that the Sun Oxygen Cleaner doesn't work correctly with acids. To properly rinse the cleaner from the bottles (or any equipment) it should get a good 3-5 rinses with hot water. I would fill the sink with warm-hot water and submerge the bottle once, drain, then sanitize. I wasn't rinsing the first bottles thoroughly, and then I was diluting the rinse water each time as well. To rectify this issue I am going to purchase a jet type bottle washer that attaches to the sink. You turn on the hot water, turn the bottle over, press it down over the nozzle, and it sprays the hot water all over the inside. Repeat a few times and then sanitize. Another cool thing about a hot water Oxy soak is that it removes labels easily, and typically breaks up any gunk inside the bottles (still give it a good scrub with a bottle brush to be sure).

Sanitizing: This is where you take the previously cleaned (all debris, gunk, etc, removed) bottles and kill off most (if not all) of the bacteria and wild yeast that might be in/on them. Options for effectively sanitizing the bottles include baking, boiling, and steaming them. Baking will effectively sterilize the bottles killing any and everything in them. It will also degrade the stability of the glass which may lead to bottle bombs, or broken necks in the future. Boiling is very effective, yet how do you fit ~ 60 bottles into a pot of water? And even if you can get them in, how do you avoid the current of the boil crashing the bottles into the wall or each other? The third option is using the dishwasher. In this method, you remove all dishes from the dishwasher and give it a good cleaning inside (wipe down the walls, make sure there are no food particles on the bottom). Some may want to open up the insides and give it a through cleaning (be prepared, I hear this is putridly disgusting). Once it is clean, fill it with bottles, and run it with out any detergents and have it set to high heat and heated dry/sanitize cycle. Once this is done, your bottles are clean, sanitary, and on a sanitized shelf for bottling. If you bottle from the dishwasher (as I do) then any beer that spills on the opened door is just dumped into the dishwasher once you are done, and goes down the drain. Of course with as anal as I am now with everything that has happened, I will most likely take these bottles and hit them with StarSan, then place them back into the dishwasher to double sanitize.