Who Can Use This? Brewers, Cellar, Production Managers

IPAs along with other hoppy beer styles are continually a taproom favorite, and customers’ love of hops doesn’t seem to have an end in sight. When meeting this demand, the incidence of brewers performing the task of dry hopping increases, which in turn increases the risk of costly beer loss from eruptive hop volcanoes and even costlier worker injury due to the inherent hazards associated with the task.

Dry hopping hazards can be mitigated by first understanding the possible hazards associated with each step of the dry hop procedure and then choosing ways to eliminate or control those hazards.

Using the information in this post along with a downloadable checklist, brewers can begin to develop a safe and successful dry hopping process and Standard Operating Procedure (SOP) for their workplace by bringing awareness to general dry hopping hazards such as pressure and asphyxiating gases, and hazard control strategies such as proper ladder use and knowledge of equipment limitations and fundamental safety principles.

What Can Go Wrong?

• Flying and falling objects, such as a tri-clamp coin
• Exposure to high levels of carbon dioxide (CO₂) or other asphyxiants
• Falling or getting knocked off a ladder or platform
• Catastrophic tank failure due to over-pressurization from a clogged pressure relief valve (PRV)
• Costly beer loss from a hop volcano, which happens when beer, hops, and CO₂ violently erupt out of a fermenter from the port where hops are added during the dry hop

Keep in mind, these hazards are exacerbated by rushing and multitasking. Extra time, planning, and mindfulness increase safety and reduce risk of beer loss.

What Should Be Done Before Dry Hopping?

• ​​​Create enough space. When planning the brewery layout, ensure adequate space between the top of the tank and the ceiling to allow for safe access to the dry hop port.
• ​​Assess the hazards of the dry hop operation and equipment.
• ​Write an SOP. Put specific details from the hazard assessment into the SOP.
• ​Train and educate staff. Allow only trained employees to perform dry hopping. During training, talk through protocols in the event of a hop volcano.
• ​​Do not overfill the fermenter. Fermenters are typically designed with 25% to 35% free headspace to accommodate expansion during active fermentation and shouldn’t be filled beyond 65 to 75% full, depending on manufacturer design.
• Schedule extra time to allow for unrushed, safe dry hopping procedures and to depressurize the fermenter adequately.

What To Wear To Stay Safe?

A fall restraint is required if dry hopping on top of a tank but not required if the operator remains on a ladder.

How Do I Dry Hop Safely?

• ​​First, depressurize the tank.  This is step one to ensure the hop port can be opened safely.
• Use the right tool to access the dry hop port. A platform, lift, engineered catwalk, rolling staircase, and hop dosing equipment are all options. If using a ladder, it is preferable to use one that is Type IA-rated, 300-pound working capacity, and made of non-conductive fiberglass.
• Be aware of wet or hot conditions. Chemicals, especially caustic, can make floors and rungs slippery.
• ​​Focus on the task at hand. Be present with the hops and pay attention through the whole act of dry hopping. If the ladder starts to move, a hop volcano forms, or the CO₂ detector alarms, calmly back away from the situation and reassess the hazards.
• ​​Monitor for CO₂ exposure. Breathing off-gassed CO₂ directly can cause dizziness or unconsciousness. Know the warning signs of CO₂ exposure and get fresh air immediately if exposure is suspected. Use a gas detector (if available), clipped to the shirt of the employee performing the dry hop.
• Stand out of the line of fire, then burp. Instead of standing directly above or over any port when opening, stand to the side of the port. Even after tank depressurization, some amount of pressure may likely remain in the tank. Stand aside to prevent injury from any flying hardware. Nobody should stand below the port either.  Then carefully open the port to release, or “burp,” excess pressure before fully opening.
• ​​Slowly add hops as opposed to all at once. Periodic pauses in your hop addition allow the beer a chance to off-gas in smaller intervals instead of all at once (hop volcano).

Quick Ladder Safety Graphics

Lastly, for more on dry hopping hazards and prevention, check out the High Stakes while Dry Hopping Craft Brewers Conference® (CBC®) seminar.