As you continue to refine your craft and scale your operations, quality control has never been more critical. In an industry with razor-thin margins and crowded shelf space, traditional plating methods are increasingly being complemented by—and in some cases giving way to—polymerase chain reaction (PCR) testing because of its increased speed, accuracy, and ease of use. Here we look at some key factors to consider as you look at integrating PCR testing into your brewery’s QC program.
Understanding PCR Sensitivity
PCR testing delivers significantly faster results than traditional methods—often in hours rather than days, letting you make quicker product-release decisions, reduce hold times, and avoid costly delays.
More than just a faster time to result, the power of PCR—and its most significant differentiation from traditional plating methods—is increased testing sensitivity. PCR’s multiplexing capabilities can also deliver results that go beyond simple pass/fail detection to offer more detailed insights into potential risks, enabling you to take proactive preventative measures.
When you’re evaluating how you can integrate PCR tools into your existing QC processes, it’s important to remember that sensitivity claims rely on several variables that are specific to target specificity, applications, and sample preparation. To truly gain the sensitivity, time, and use benefits of PCR, don’t hesitate to ask your solution provider to share the Limit of Detection (LOD) for each specific PCR test in your portfolio and how it can vary by application or sample-preparation methods. This information should be readily available and will help you understand the individual contribution of each component to the overall testing plan. This is important if your solution is enrichment-based or offers a “same day” time to result.
Additional Factors to Consider
Effectively evaluating sensitivity claims is only the first step in selecting the right PCR solution. Additional critical considerations for PCR solutions and implementation include:
- Instrumentation and Test Type—PCR methodology can flexibly meet the specifications of a wide variety of QC programs and production facilities. Offerings can be designed for single-target detection or for multichannel testing in one tube; to run on closed systems (working exclusively with its own brand of tests) or open systems (ability to run other tests and homemade assays); and can even offer fully automated software for objective results interpretation to help you avoid user subjectivity in interpreting results. The versatility of the technology means that you can take advantage of the methodology’s benefits no matter the size of your operation or QC program.
- Sample Strategy—One of PCR’s greatest strengths is its ability to test not just in finished products, but across the entire production process, including in raw materials, in-process samples, and packaging environments. This capability, paired with increased sensitivity of the technology, requires a comprehensive sampling strategy that accounts for both live- and dead-cell DNA detection (viability) in the QC process. During beer fermentation and processing, you may use several mitigation efforts to minimize spoilers, and these processes can lead to many dead cells in a sample. The presence of these dead cells can paint an incomplete or inaccurate picture of the true spoilage risk in a sample. bioMérieux’s Viability Kit distinguishes viable from nonviable microorganisms detected on PCR, helping to ensure precise spoiler detection to safeguard your supply chain. This ready-to-use sample treatment method helps reduce seemingly false positives, avoids unnecessary follow-up tests, supports getting products to market, and streamlines operational decision-making.
- Training and Integration—Even with simplified workflows, integrating PCR testing into your facility requires training to ensure confidence in your results. bioMérieux’s training process includes a representative onsite in your brewery to train your team on the solution, followed by regular site visits and consultations to help optimize the solution to your facility. If you’re expanding your company’s offerings, you can’t assume that sample preparation that is optimized and validated for beer testing will function properly on other beverage categories. Such assumptions can lead to ambiguous results and time-intensive confirmation processes. bioMérieux can leverage their R&D team’s expertise to develop validated, specialized sample preparations for diverse beverage categories beyond beer—such as RTDs, seltzers, and other emerging beverage categories.
- Cost in use—While PCR tests can provide faster and more accurate results, the true cost-per-test goes beyond the price tag of the test itself. QC costs should also factor in personnel overhead—the most significant lab resource. This is particularly true with intensive tasks associated with DIY molecular tests, such as preparing master mix raw materials and convoluted sample-prep protocols. When you’re choosing a PCR solution, look for one that minimizes hands-on time—or includes pre-prepared components—to reduce the operational overhead and improve cost-efficiency.
A Strategic Shift toward Proactive Quality Management
Integrating PCR testing with a traditional plating approach is more than just a technology upgrade. It’s a shift toward proactive, real-time quality management. With all the pressures you face today—rising costs, hitting operational efficiency targets, incorporating sustainability objectives, meticulously managing overhead—the ability to detect and differentiate spoilers early and act quickly is invaluable.
Having a more reliable, flexible QC process isn’t just nice—it’s a no-brainer. Want to learn more about how bioMérieux’s diagnostic solutions can improve your brewing operations? Visit: our website.