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 Expert  727238

Expert in Brewhouse Operations and Process Maximization, Fermenting Operations, and Stratified Fermentation


Available for your Consulting and Expert Witness Needs

Idaho (ID)
USA
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise:

Listed with other top experts in: 

Expert has continuously improved a large scale brewhouse operation, generating savings of up to 566,000 lbs of grain per month through increases in extraction efficiency, going from 88.5% to 92.5%. During this effort Expert and his team increased the brew size from 695 bbls to 920 bbls / brew, while simultaneously reducing the brew cycle from 165 min / brew to 144 Minutes per brew. Successes with this effort helped Expert have an unusual depth of understanding of how to make the process work for maximum flow and quality thorughout the process. These efforts culminated in selection of Expert as the Brewing side Project Manager for a $65 MM Modernization project to Modernize the Brewhouse and Fermenting areas, converting it from Discreet Logic (PLC 5's) to Siemen's S-88 Batch. This effort further improved extract efficiency and increased capacity, by reducing the mash in cycle to 135 minutes per brew. The increase in capacity was particularly effective in providing time to perform all scheduled maintenace during the week, instead of weekends. By design, all lines and vessels could be CIP'd daily, without a loss in production. Expert's 30 person team was responsible for writing all Batch Recipes. training and start up. Expert's other brewhouse efforts included identifying and correcting a number of utilities related issues. Expert has used all of this brewhouse related knowledge to solve issues within the craft industry such as flavor matching a new brewhouse to the beer produced in the old brewhouse; and increasing capacity in another operation. In fermenting, Expert was instrumental in discovering and correcting the mechanism causing stratification in fermenters. This reduced process time by days, improved the quality of harvested yeast and improved the quality of beer in the processes where stratification had occured. Expert also succesfully found methods to pitch yeast within +/- 0.5 MM cells / Ml where the former range had been +/- 1.5 MM cells / ml. Combined with sucesses at modifying the fermenter cooldown, final beer quality was significantly improved, both analytically and in taste.
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brewery

Expert has solved several brewing microbial problems and has effectively eliminated a stubborn flavor negative biofilm. Expert discovered and corrected a cellars wide cip issue that was causing increasing levels of infection. A second issue discovered and corrected involved how and why a UV Sterilizer was allowing bacteria to survive the conditions. The issue was corrected by adding one additional cleaning step, that while in the equipment's procedures, had never been implemented by the plant. The biofilm issue was discovered by on site hand exploration of the piping. It was corrected by changing the cip procedure to assure turrbulent flow, and by adjusting frequency pf cleaning and caustic strength/ this discovery became part of an ROI project for Quality modifications
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brewing science

Prepare and Deliver Expert Brewing Talks and Papers: Expert brewing competency was effectively used to teach "Practical Brewhouse Operations" many times at the Master Brewer's Annual classes in Madison Wisconsin. He has had had several knowledgeable peer reviewed papers published in the MBAA Technical Quarterly. These include "Stratified Fermentations", which received a coveted Inge Russell Best Paper Award for the ingenious solution of a practical problem. This problem required detail observations, collection and interpretation of data as well as follow up to assure the problem was solved. "How to make really Bad Wort and Beer" , a darkly humorous look at product Quality. This paper demonstrates the proficiency of Expert's Brewing knowledge "Thermostatic Air Vents and Vacuum Breakers" . This paper demonstrates a working knowledge of an interaction of Brewing with Utilities

Expert has authored numerous practical brewing white papers published and distributed by Pro Engineering in Milwaukee http://prowm.com/pro_tech_notes.html

Expert is a liaison member of the MBAA Higher Education Committee, helping colleges interested in a Pathway to Recognition for their brewing program. Most recently Expert Helped Flathead Valley Community College select their brewing equipment, helped find a suitable contractor and he taught Introduction to Fermented Foods and Beverages.

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beer


Show Secondary and Basic Areas of Expertise
Localities:
Expert may consult nationally and internationally, and is also local to the following cities: Nampa, Idaho.

Education:
Year   Degree   Subject   Institution  
1968   BS   Industrial Management / Industrial Engineering   Fairleigh Dickinson University  

Work History:
Years   Employer   Department   Title   Responsibilities

2010 to

 

(Undisclosed)

 

Brewing

 

Consultant

 

He audited the Brewing process and equipment, making specific recommendations that addressed processs opportunities of special interest to the owners. He provided insight on ways to improve extract efficiency and how that improvement could be used to justify projects with an ROI.

2010 to 2010

 

Goose Island Brewing Co

 

Brewing

 

Consultant

 

Provide specific recommendations to improve capacity and improve extract recovery. Capacity and yield efforts included equipment and procedural recommendations.

2008 to 2009

 

Dogfish Head Craft Brewery

 

Brewing

 

Consultant

 

He consulted on a capacity growth management project. He was able to make improvements in run off and in the areas of brewhouse utilities. He provided detailed information on steps needed to meet plant growth, including a modeling of the process on Microsoft Project. He was asked to assist with Training and has provided names of suitable SOP developers.

2007 to 2008

 

Alexus-Nex Gen

 

Entreprenurial Venture

 

Consultant

 

He provided practical brewing consultations for an entrepreneurial effort to start a Nigerian Brewing operation. Responsibilities included product formulation, capacity calculations and efforts to secure an interim contract brewing beer supply while the brewery in Africa was upgraded.

2007 to 2007

 

Deschutes Brewery

 

Brewing

 

Project Leader

 

He consulted as a Project Leader for a Dry Hopping Improvement Modification project.

2005 to 2007

 

Huppmann GMBH / Deschutes Brewery

 


 

Consultant

 

Consulted from a “new side” Brewhouse operation to the preferred beer from the “old side” at the Deschutes Brewery, Bend, OR. He was able to make key identifiable flavor improvements and a number of Brewhouse process improvements during the consultation period. Key items included reduction of Lauter tub cuts from 8 to 2; reductions in run-off time, wort clarity improvements and distinct wort and beer flavor improvements. Loss of thermostatic siphoning in the kettle was corrected at the site of the issue. The plant continued with improvements after the consultation period and the product involved is now made successfully on the new side.

1968 to 2003

 

Anheuser-Busch, Inc.

 

Various

 

Various

 

Positions held include: Project Manager for a a $65M project to automate, recontrol and increase the capacity of the Baldwinsville, NY, brewing plant; Assistant Brewmaster; Manager of Cost Control (Corporate Brewing Department); and Section Manager of Brewing in Corp. Industrial Engineering.

2014 to 2016

 

(Undisclosed)

 

Brewing Project

 

Consultant

 

Assist Expert's Firm with design and start up. Act as a beer taste consultant. work was periodic in nature.

2015 to 2015

 

Flathead Valley Community College

 

Brewing System And Education

 

Consultant, Teacher

 

provide system design expertise as they started up their Brewing program. Also taught Introduction to Fermented Foods and Beverages

2016 to 2016

 

(Undisclosed)

 

Brewing capacity increase project

 

Consultant

 

Recommend specific methods to increase capacity and improve flavor

2013 to 2014

 

Budweiser Mobile Beer School

 

Expert Speaker

 

Brewmaster Speaker

 

Appear at venues and talk about beer


Career Accomplishments:
Associations/Societies

MBAA (Master Brewers Association of the Americas)

Professional Appointments

Editorial Reviewer for the IBD Editor for books and atricles relating to brewing, Subdifision Board Member, Eagle Springs subdivision; Mobile Beer School Intstructor for Anheuser-Busch; Board member on the Radisson subdivision; Beer judge for the Upstate Home Brewers events; District Western NY MBAA (all positions held). MBAA Higher Education Committee member

Awards/Recognition

'Editor's Choice Award' for an MBAA Technical Quarterly article on stratified fermentations (2008); 'Inge Russell Award' for the best Technical paper of 2008 (awarded in 2009). Editor's choice award for the Art and Science of Brewing Really bad wort and Beer.


Publications:
Publications and Patents Summary

He has one published article on stratified fermentations, and has spoken on numerous occasions at MBAA conventions.

Selected Publications and Publishers  
 - MBAA Technical Quarterly Vol 45 #2 2008  
 - Pro Engineering  

Government Experience:
Years   Agency   Role   Description
2005 to 2010   Eagle Springs Subdivision HOA   Board Member in charge of Facilities   develop and manage subdivision projects

Consulting Services:
Click the green button above to contact Expert for a free initial screening call regarding your expert consulting needs.  Expert is available for consulting to corporate, legal and government clients.  Remember, your initial screening call to speak with Expert is free.

Expert Witness:
Expert Witness Experience Summary:
Provided expert opinion on a South African taxation decision case.
Click the green button above to contact Expert for a free initial screening call regarding expert testimony, litigation consulting and support, forensic services, or any related expert witness services.  A few litigation needs include product liability, personal injury, economic loss, intellectual property (patent, trademark, trade secret, copyright), and insurance matters.  Remember, your initial screening call to speak with Expert is free.

International Experience:
Years   Country / Region   Summary
2015 to 2015   South Africa   provide expert opinion on brewing products

Language Skills:
Foreign Language   Description
English   Expert/Native Tongue
German   Basic education in German and Latin

Market Research:
Personal presence on LinkedIn and on my website www.davidkapral.com. Listed as a craft beer resource person for ProEngineering in Milwaukee WI.

Click the green button above to contact Expert for a free initial screening call regarding your marketing research, industry research, and company research needs.  For research needs involving multiple experts or secondary research, a Research Director can be assigned to coordinate the work into a custom report for you as a potentially quicker and more cost effective alternative to doing this work yourself or hiring a boutique consultancy.  Remember, your initial screening call to speak with Expert is free.

Additional Skills and Services:
Training/Seminars

MBAA Brewing School, Madison, WI; Anheuser-Busch Brewing Technology Course; Anheuser-Busch Brewing Engineering Course; Siebel's Microbiology Course.


 

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