Automation and the Brewing Process
by Sara Nichols
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Siemens - Brewing Industry Pedigree
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SIEMENS - Partner of Brewing industry for more than 100 years
1897
Brewery F. Oettler Weissenfels a.d. Saale installs as one of the first of its kind
decentralized electrical motors from Siemens
1901
Electrification of Brauhaus Nuremberg by Siemens
1973
Simatic Industry controller from Siemens are used in breweries
1977
Braumat: The first controller based recipe controlled automation system for
breweries occurred in the market
1993:
Braumat uses the first time Windows PCs as basis of he human machine interface
1997
Implementation of graphical recipe system
2003
Introduction of area overlapping control
2012
For the first time Chinese as operator language is implemented
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Simply, Siemens has been associated
with Brewing for a long time
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Automation – “Is it only for Large Breweries”?
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Of course It's not ...
Has Brewing Changed over the last 300 years?
Not really
Has technology changed?
Yes and the rate of change is speeding up
Has consumer behaviour, demands & expectations changed?
Yes and a lot of this change is fuelled by technology
So where does automation fit and what are the challenges? Is it smoke and mirrors?
Before we go deeper, lets look at the future ...
Lets look at Industry 4.0, Internet of Things (IoT) .... Big Data, Cyber Physical networks
Industry 4.0
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Types of Manufacturing- Discrete / Process
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Discrete Manufacturing vs Process Manufacturing
Discrete / Digital Factory
Is it present? Yes / No
How many, how often
Has a complex BoM
Typically assembles Products
Has conveyers
Process / Variable
How much
How long
How Hot / cold
Works to a recipe
Typically move liquid, powder, fluids ...
Is often a batch driven process
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Automation requirements for Discrete & Process Control ...
FIELD DEVICES
FIELD DEVICES
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Controlling / Automating the Brewing
‘Process’
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Brewing is a Process – Automation Options
So what are the control options?
Hardwired
Relays, Timers, dedicated control devices, push buttons, lamps
Programmable Logic Controllers PLC / Human Machine Interface HMI / Supervisory Control
And Data Acquisition SCADA
Dedicated Brewing Solutions - Recipe, Batch & Routing management
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Automation - Temperature Control
Brew House
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Fermentation
The temperature and time of mashing are
critical in determining the quality and
characteristics of the final beer.
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Fermentation produces
heat. The temperature of
the fermentation vessel is
controlled using cooling
jackets around the
vessel. Controlling this
temperature prevents
damage to the yeast and
controls the speed of the
fermentation.
Hard wired - What does this look like?
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What ‘Hard’ wired panels can look like ...
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PLC HMI / SCADA Control
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PLC, HMI, SCADA – What the hardware looks like
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PLC HMI / SCADA
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Dedicated Brewing Solutions
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Temperature Control – Dedicated Brewing Solution
Brew House
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Fermentation
Dedicated Brewing Solution - What the hardware looks like
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Temperature Control – Dedicated Brewery Solution
Process
Control
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§Are a comprehensive process control system for brewing
industry
§Have objects and libraries embedded for all control & process
requirements
§ Provides easy to use; administration, engineering,
visualization and recipe design can be conducted by one
engineer with limited training efforts
§Delivers powerful recipe control as well as an efficient route
control
§Allows for software modifications during production with
extremely short turnaround times
§Embeds event management and process history
Process Instrumentation ...
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Is potentially the same field device
(Instrument) whichever control methodology
is employed
If you can’t measure it, you can’t control it
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Programming considerations ...
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The Functional Specification (FDS) and User Specification (URS) ...
FDS
Operational Considerations
What opens
When does it open, before or after what
For how long
How much
How often
What happens next
URS
What information do you need to see back from the process
How do you want to see it
What information do you want to be able to input to the process
How do you want to do this?
from a mobile device,
a discrete device (Push button),
through a shop floor terminal
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What is the level of Automation
Routing
Hop Back ...
How many recipes
How many batches
How many staff
How many tanks
How many brews per day
CIP
GMP’s
Blending ..?
Programming approaches
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Modern Programming environment
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Control Process Options pros and cons
Hardwired
An electrician can fault find
Process is typically manual
Can start very small and make it up as you go
Often considered the cheapest option
The process is typically dependent on human input management and over-seeing totally on people
Any process data capture would need to be manual
PLC / HMI / SCADA (Purity, Thornbridge, Camden Town ...)
Should be based on a well developed user & functional scope / understanding
Includes many of the library objects found in batch applications
Can easily incorporate alarms and history
Potentially needs to be modified with recipe changes
Can be used to collect necessary process information to satisfy for regulatory compliance
Requires support from a skilled person
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Control Process Options pros and cons
Dedicated Brewing Solutions - Recipe, Batch & Routing
Larger Breweries typically use a dedicated Batch application for Brewing e.g.
Heineken, BrewDog, Hall & Woodhouse, Adnams ...
Primary control is PC / Server based
The solution supports all user & business interface in respect to the processes
Allows for recipe development within the solution (no coding changes)
Has alarm and history functions built in
Is programmed in function block
Gives agility & flexibility to the Brewhouse
Provides robust process control to deliver repeatability and optimised use of raw materials
Requires a more specialist skill set to deliver solution
Captures data for tracking & tracing, optimizing and regulatory compliance
Captures data to support quantity control and associated laboratory requirements
Retro-fitting a Batch solution means starting again
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Commercial realities
Engineering resource is becoming harder to find?
How to support and maintain?
Remote access and viability
Art or science?
Increasing record keeping requirements from off trade
Automation comes at a cost
Implementing the right automation delivers value
End
User
Consultant
Automation
Supplier
it’s not magic
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Solution
Provider
Questions?
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Thank you for your attention!
Sara Nichols – Account Development Manager
Siemens plc
Digital Factory & Process Industries and Drives
Factory Automation
Sir William Siemens House
Princess Road
Manchester
M20 2UR
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