Recipe Adjustment is an additional module that can be added to your Orchestrated database. This feature enables you to dynamically adjust your production orders based on the batch of hops and their alpha acid. If you are interested in purchasing this module, please submit a Support ticket to start the process.
Breweries need to adjust the amount of bittering hops that go into a beer, based on the alpha acid of the hops. Based on the recipe’s IBUs (international bittering units) the brewer will need to use a certain amount of hops. The higher the alpha acid of the hops, the less amount required to reach a certain level of IBUs. The alpha acid determines the bitterness of the hops, so if the alpha acid changes, the brewery needs to alter the amount of hops that go into a brew to keep the same amount of bitterness of the beer. The alpha acid is input for each batch, so we’re able to pull that in and update the recipe in real time based on certain calculations.
Recipe adjustment is related to Advanced QC functionality, but operates on a separate license.
To use the Recipe Adjustment feature, you first need to assign the license to your user. You can do this by going to Administration>License>Orchestrated Licensing. Here you can select the checkbox under the Recipe Adjustment column for your user.
Once you add the license and restart your session you will gain access to a few additional items. You’ll now be able to see the table where you enter in the hops alpha acid by batch in Inventory>Hops QC. You’ll also be able to see the recipe adjustment button that dynamically updates the production orders in Production>Production Forms>Brew Sheet. There are also several other columns in specific windows that are important for recipe adjustment and can be added by the Form Settings in the toolbar.
The next step for configuration is to rename the “Weight In” column on the production order to “Original Qty”, as OBeer repurposes this field for the recipe adjustment feature. You can do this by holding “Ctrl” on your keyboard and double-clicking on the column header.
How to Use
Step 1: Update the Bill of Materials
The user needs to Production Qty, Production UoM and the Recipe Adjustable columns. The quantity and unit of measure columns will be specific to their recipe. The recipe adjustable column should be set to “Y” for all hops they want to adjust based on the alpha acid.
Step 2: Update Hops QC
When hops are received into inventory, the user will need to update the alpha acid for all the batches. The only field that is editable in this table is the Alpha Acid column and should be entered by the user. If any other batch related fields need to be updated the user and do this in Inventory>Item Management>Batches>Batch Details. If there are multiple batches for the same item, the system will calculate from the batch with the oldest in-date.
Step 3: Create Production Order
When you create the production order for wort the “Production UoM” will be “BU” and the “Production Qty” will be from the original recipe from the bill of material. To process the recipe adjustment on the Brew Sheet you will first need to release the production order.
Step 4: Process Recipe Adjustment
From the Brew Sheet, the user will highlight the row of the desired production order and click the “Adjust” button under the “Recipe” section on the left side of the window.
If processed successfully, you might see a brief system message pop up and will remaining on the Brew Sheet. In the background the system has done a series of checks and calculations, then updated the production order. If you drill into the production order you will see that the “Production UoM” has chaged to “grams”, the standard UoM for hops.
Below is a summary of what happened to the production order:
- Move data in the Qty column into the Original Quantity column
- Move data in the Prod Qty to the BU column for each of the rows flagged as "Y" for Recipe Adjust
- Pull in the alpha acid details from oldest batch for each of the rows flagged as "Y" for Recipe Adjust
- Pull in the Alpha Acid for each of the rows flagged as "Y" for Recipe Adjust
- Calculate the quantity of grams and Lbs Qty for each of the rows flagged as "Y" for Recipe Adjust
- Update the Prod Qty with the quantity of grams for each of the rows flagged as "Y" for Recipe Adjust
- Update the Prod UoM to "Gram" for each of the rows flagged as "Y" for Recipe Adjust
- Update the “Planned Qty” column with new quantity in "Lbs" for each of the rows flagged as "Y" for Recipe Adjust
While the “Production UoM” is shown in grams, the inventory transaction is still processed per the Inventory UoM on the Item Master Data record.
It’s also important to note is that the recipe adjustment will not process successfully if the updated “Planned Qty” is less than 0.01. For example, for a 5.5 alpha acid the lowest your IBU can be is 24.95 (before there’s no update to make). You will know it wasn’t processed successfully because none of the columns will have been updated.
The calculation used in the system for the “Production Qty” in grams and “Planned Qty” updated by the recipe adjustment is included below:
BU / AA (Alpha Acids) = Gram
Gram / 453.592 = Lbs
100 / 4 = 25[g]
25 / 453.592 = 0.06 Lbs