Not All Hoses Are Created Equal: The Importance of Quality in the Brewery Industry

At first glance, a hose may seem like just another piece of equipment, but in the food and beverage industry—particularly in brewing—the materials and manufacturing processes used can significantly impact the final product’s quality.

The Cost of Poor Choices

There have been instances where customers reported strange odours tainting their beer, and almost every time, the issue was traced back to the use of inappropriate materials. For example, while NBR (Nitrile Butadiene Rubber) is suitable for fatty foods and dairy applications, it is not ideal for brewery use.

The Technical Explanation

The reason lies in the properties of different hose compounds, which play a crucial role in brewing. NBR is excellent for oils and fatty food/liquid-based products, but beer, with its unique composition, reacts differently to these materials. Over time, using NBR hoses can cause the liner to leach undesirable elements into the beer, adversely affecting flavour, aroma, and overall quality.

In addition to the hose liner material, the manufacturing process is equally important in influencing hose quality. Did you know that some manufacturers cut costs by using industrial-grade steel mandrels instead of stainless steel to form hoses? In some cases, these mandrels are not adequately cleaned between production runs, leading to contamination from oils, dirt, or even foreign bodies such as insects. Reports have even documented debris or imprints of insects on the hose liner itself. The first signs of such poor manufacturing practices often manifest as greasy, dirty liners, strange odours, or premature cracking as lower-quality materials begin to break down.

Fillers and Releasing Agents: Hidden Risks

Another cost-saving measure employed by some manufacturers is to add fillers, such as chalk, talc, calcium carbonate, and other compounds, to the base material. While this practice lowers expenses, it compromises the integrity of the hose. The degradation caused by fillers is not immediately visible, but over time, hoses containing these additives can develop micro-cracks, degrade more quickly, and begin releasing unpleasant odours into the beer.

Another critical part of producing mandrel-built rubber hoses, such as brewery hoses, involves using releasing agents to facilitate removal of the cured hose from the mandrel. These agents prevent sticking and ensure a smooth finish on the hose. However, if a non-FDA-approved releasing agent is used, it can permeate into the hose liner and eventually leach into the beer over time. This slow contamination can produce subtle off-flavours in the final product—something breweries, where consistency and quality are paramount, simply cannot afford.

Common Filling Compounds in the Rubber Industry

Here are some common fillers utilised in rubber production:

  • Calcium Carbonate: Widely used as an inexpensive filler that enhances tensile strength and processing characteristics of rubber.
  • Talc: A low-cost filler that improves the flow properties of rubber during processing while reducing production costs.
  • Chalk: Similar to calcium carbonate, chalk lowers costs and provides some reinforcement.
  • Bentonite: A type of clay that can improve the viscosity and provide reinforcement in rubber compounds.
  • Recycled Rubber: Some manufacturers incorporate recycled rubber materials to reduce costs and promote sustainability, though quality and performance can vary widely.

Impacts of Using Filling Compounds

While these fillers can significantly reduce production costs, they often come with trade-offs, such as:

  • Reduced Mechanical Properties: Fillers may compromise tensile strength, flexibility, and overall durability of the rubber hose.
  • Odour and Taste Transfer: In food-grade applications, fillers can lead to undesirable odours or tastes if not carefully selected.
  • Micro-Cracking: Some fillers can cause rubber to develop micro-cracks over time, affecting hose longevity.

“A Hose Is Not Just a Hose”: Understanding the Value of Quality

A notable instance involved a brewer who questioned why higher-quality hoses were more expensive, stating, “A hose is just a hose.” In response, it was emphasised that, just as not all beers are the same, the same applies to hoses. The brewer was asked if he considered his beer to be like any other beer—a question that highlighted the importance of quality ingredients in every aspect of the brewing process, including the equipment.

This brewer eventually became a loyal customer, recognising that investing in high-grade Brewflex hose assemblies helps ensure the quality and consistency of his product.

Investing in Quality Protects Your Brand

For those in the brewing industry, it is essential to understand that not all hoses are created equal. By investing in high-quality hoses designed specifically for brewery processes, businesses safeguard not only the taste and aroma of their beer but also their brand's reputation. While cutting corners may seem cost-effective, the long-term consequences of using inferior hoses—such as contamination, unpleasant odours, and premature degradation—can be far more expensive.

So Which Hose Is Best for My Brewery?

When choosing the right hose for beer production, at Flextech, we believe it is crucial to avoid batch contamination, taste or odour transfer, and ensure FDA compliance. Below, we provide some key facts about why we recommend and why so many customers rely on our Brewflex brewery hose to help them make the best choice for their brewery.

Butyl Rubber: The Optimal Choice for Breweries in Beer Production

Butyl rubber is often considered the best choice for breweries in beer production due to its unique properties that cater specifically to brewing process demands. Here are the key factors when choosing rubber liners for beer production, including taste and odour transfer, chemical resistance, temperature tolerance, gas permeability, and compliance with food safety regulations:

1. Butyl Rubber

Advantages:

  • Low Gas Permeability: Resists oxygen and other gases, crucial for preventing oxidation and maintaining beer freshness.
  • Good Chemical Resistance: Resists various chemicals, including acids and bases commonly used for CIP cleaning.
  • High-Temperature Tolerance: Withstands -40℃ to 120℃, suitable for hot and cold applications in brewing.
  • Food Safety Compliance: Meets FDA regulations for food contact.
  • Low Taste and Odour Transfer: Does not impart flavours or odours, preserving the beer’s taste profile.
  • Flexibility: Remains flexible even at low temperatures, aiding handling and installation.

Disadvantages:

  • Less flexible than EPDM, which can make handling short lengths more challenging.


2. EPDM Rubber (Ethylene Propylene Diene Monomer)

Advantages:

  • Good Chemical Resistance: Resistant to many acids and bases, beneficial in brewing processes.
  • Excellent Weather Resistance: Highly resistant to UV radiation, ozone, and ageing.
  • High-Temperature Tolerance: Withstands -40℃ to 120℃, suitable for various brewing applications.
  • Low Water Absorption: Maintains beer quality without altering flavour.
  • Flexibility: Remains flexible at low temperatures, aiding in handling and installation.

Disadvantages:

  • Higher gas permeability than butyl rubber, potentially allowing oxygen ingress and spoilage.


3. EPDM Rubber (Ethylene Propylene Diene Monomer)

Advantages:

  • Excellent Oil Resistance: Ideal for breweries handling oil-based products.
  • Good Mechanical Properties: High tensile strength and abrasion resistance enhance durability.
  • Temperature Resistance: Handles -30℃ to 100℃, making it versatile for brewing.

Disadvantages:

  • Higher gas permeability and limited chemical resistance, which may affect beer quality.