Enterprise Brew Overview
Why Enterprise Brew?
Craft brewers are faced with an endless array of challenges on a daily basis in order to keep their businesses
moving forward. Managing inventory levels, product formulations and product quality, distribution and sales
channels, cash flow, insurance and legal items are just part of a craft brewer’s daily task list. Those who
successfully navigate through these tasks are rewarded with business growth, which in turn creates an entirely
new set of challenges many of which focus on increasing production capacity. For some, this means adding a
few new tanks, while for others this may mean either expanding an existing plant or building an entirely new
plant altogether. In either case, dozens of production capacity related engineering decisions need to be
addressed.
Unfortunately, most craft brewers just do not have the time or engineering capacity to support such activities
and no other vendor has the expertise, or business model to support an entire craft brewer’s enterprise.
Enterprise Brew, (EB), was designed by Providence Process Solutions, LLC, (PPS), as an enterprise wide brewing
system that supports nine fundamental services associated with existing tank upgrades, facility expansions or
new facility designs. These services include:
☆ Tank System Design – Brew house, fermentation, conditioning, brite, hot / cold liquor, custom.
☆ Process Automation – Available from single tank to enterprise wide process automation.
☆ Manufacturing Execution Systems – For production planning, OEE, process optimization.
☆ Business ERP Software – Inventory management, formulations, orders management, financials.
☆ Auxiliary Process Systems – Refrigeration, coolers, boiler / heat exchange, & air compression systems.
☆ Electrical Facility Design – Power distribution, lighting, data networks, phone, audio.
☆ Vendor Coordination – Develop specifications, review engineering requirements, solicit proposals.
☆ Project Management – Using Microsoft Project and PMI standards. Focus – Budget, time, specifications.
☆ Strategic Planning and Finance - Strategic business planning with finance procurement.
This holistic approach to brewery design provides peace of mind to the craft brewer by knowing that all their
equipment is properly sized to support capacity targets with room for growth, all equipment is designed for
maximum interoperability, all vendor activities are properly coordinated, and all data systems are designed to
communicate from plant floor to top floor seamlessly. Attention to detail is an absolutely critical part of EB.
Each service is offered independently or as a coordinated group depending on the project requirements.
There are also several options within each service that offer a craft brewer unique sets of features and
associated costs in order to support virtually any budget!
Providence Process Solutions, LLC - vern@prov-ps.com - Cell: 262.770.1292
Enterprise Brew Overview
Enterprise Brew’s Team?
Due to the broad scope of supply offered under EB, several key preferred business partners were individually
selected to support a variety of technologies, services and equipment based on their industry / application
knowledge, technological capabilities, competitive price models, and overall level of professionalism. Each of
these partners work in concert with each other under the leadership of PPS and participate in the system design
process from day one. The EB team model is defined below:
American
Boiler
Quality Tank
Solutions
Badgerland
Refrigeration
Providence
Electrical
Brewery
Finance
Data
Specialists
(ERP)
IPACT
(MES)
ESE Inc.
Automation
In addition to offering tightly integrated system solutions at competitive price levels, the EB team has worked
with one another on past projects and are familiar with how each other’s systems operate specific to their
individual product offering. This matrix of existing relationships reduces conflict, improves efficiencies and
reduces costs therein. This team based model approach has also generated a strong and positive work
environment, based on trust, well defined scope of supplies, respect and open communications. This in turn,
allows for simplified project management on behalf of PPS.
Already have a local equipment or service provider that you prefer to work with? While PPS will always lead
with Providence’s preferred business partners, we do understand and respect the importance of existing
relationships and will integrate your vendor into the EB team upon request.
Providence Process Solutions, LLC - vern@prov-ps.com - Cell: 262.770.1292
Enterprise Brew Overview
Enterprise Brew Design Methodology?
Phase 1 – Strategic Planning - Capacity planning begins with an evaluation of a craft brewer’s business growth
plan. This plan is critical as it not only defines the brewer’s anticipated 3-5 year sales expectations, but it also
includes a variety of other business metrics that financial institutions often request in order to underwrite a
loan. PPS utilizes MBA Level business strategic planning methods for pro-forma cash flow, capital requirements,
distribution analysis, competitive threat, environmental considerations, SWAT analysis, and several other
business metrics that typically encompass a professional business plan.
Phase 2 – Capacity Planning - The business plan’s volume forecast is then used to size the brew house and
downstream tank capacities. These additional loads are then evaluated against existing auxiliary equipment like
the plant boiler, refrigeration system, air compression system, mill house capacity, and tank space requirements.
The bottling line and cooler space are then evaluated and a master plan is designed.
Phase 3 – Process Equipment Definition - Each sub-system is then evaluated under PPS’s guidance using PPS’s
partners so that all process sub-systems support the master business plan, properly interconnect with each
other, and are priced competitively based on each brewery’s budget and specific system requirements. PPS
coordinates all engineering data between PPS’s partners and collects all associated proposals, so that a
complete system solution with details per vendor can be presented to the craft brewer and incorporated into
the craft brewer’s business plan. Project schedules are also estimated during this initial budgetary phase.
Phase 4 – Electrical Systems Design - Another key feature to this enterprise wide systems design approach
resides in PPS’s ability to define all electrical systems requirements and incorporate all this data into a master
electrical design plan and electrical contractor bidders specification, where all electrical apparatus is specified,
lighting loads are calculated, certified drawings are created, transformers, panels and panel circuits, line voltage
drops, and load balancing is also calculated. Data and telephone communication, process control and
instrumentation, and audio system designs are also defined as part of this service and Providence coordinates all
this information with your Architectural & Engineering, (A&E Firm), and / or general contractor for additional
overall project efficiency.
Phase 5 – Project Management - Once a plan is defined and funding is procured, a project kick-off meeting is
scheduled at the brewery, where all vendors can review the entire plan, and detailed project schedules are
created by PPS. Weekly engineering / project review meetings are then led by PPS and all project management
activities are documented in either Microsoft Excel or Microsoft Project using Project Management Institute’s,
(PMI), approved standards, where schedule, budgets and specification adherence are closely monitored. Any
additional expenditures above the project plan are managed by PPS via change-orders.
Phase 6 – Post Commissioning Support - Once all equipment is installed and system commissioning / training is
performed, a project evaluation meeting is performed, where all open items are addressed and overall project
effectiveness is evaluated. PPS is always available after the project has been successfully completed to answer
any questions the craft brewer might have or assist in another project.
Providence Process Solutions, LLC - vern@prov-ps.com - Cell: 262.770.1292
Enterprise Brew Overview
Enterprise Brew Tank System Design
Overview – Pricing = Application dependent. Like a craft beer, each tank is custom
designed and manufactured in the USA, supporting the unique needs of each craft
brewer. Quality Tank Solutions tanks are known to be among the highest quality in
the industry. Bottom line…EB’s tank systems from QTS are built to last!
Typical Tank Configuration Options:
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Tank Sizes: 1 – 500 BBL’s.
Stainless – High quality 10 – 12 gage Stainless 304.
Tank Dimensions – Variable diameters and heights.
Tank Heads – Available in a variety of sizes and shapes with multiple port options.
Tank Heating / Cooling – Multiple control zones custom designed to support beer recipes.
Legs – Several options including simple leveling adjustments and load cells.
Insulation – 3 Inches high efficiency rated = standard.
Welds – Continuous, high quality material, high polish finish.
Testing – All connections and energy transfer systems factory tested.
Pumps – Fristam high efficiency, multiple varieties.
Valves – Definox high quality, multiple varieties.
Instrumentation – Anderson Instruments, RTD’s, Level.
Heat Exchangers – Tetra-Pak = shell & tube, calandria, and plate.
Configurations – Skidded or stand-alone.
Compliance – Sanitary, U/L, NEC rated.
Automation – Allen-Bradley PLC’s, VFD’s, Wonderware, Rockwell Software.
Lead Time – Application dependent, (typically 8-16 weeks).
Tank Configurations:
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Mash Tun: Custom dimensions, agitation options, automated = fill vol., strike temp.
Lauter Tun: Custom dimensions, raking options, automated = fill vol., recirc., temp / time
Kettle: Custom dimensions, various heating options, automated = hops addition, recirc., temp, times
Whirlpool: Custom dimensions, automated settling times, wort inlet port options, filter options
Fermentation: Custom dimensions, programmable temperature profiling and control
Conditioning / Brite: Custom dimensions, automated temp regulation, time in tank monitoring
CIP: Custom dimensions, skidded or stand-alone, multiple sizes, fully automated
Hot / Cold Liquor: Custom dimensions, programmable temp, level control
Providence Process Solutions, LLC - vern@prov-ps.com - Cell: 262.770.1292
Enterprise Brew Overview
Enterprise Brew Automation, (EBA)
Overview Pricing – See Table EB2. EBA was designed to optimize process control,
yield and plant floor to top floor data communications and utilizes three different
configurable architectures, each offering different value propositions to the craft
brewer. The EB Advanced and Enterprise versions were both designed to support
real time plant floor to top floor data communications utilizing Microsoft SQL Server
Database for optimized operational performance.
Option 1 – EBA Basic – $25K - $35K. This low cost manual control option utilizes Allen-Bradley standard
industrial control and two variable frequency drives in a NEMA 4X stainless steel enclosure. No PLC’s or HMI’s
are utilized, in this option and all tank temperatures are controlled using single point analog loop controllers.
EBA Basic’s scope of supply includes the brew house, fermentation, conditioning, brite and hot / cold liquor
tanks.
Option 2 – EBA Advanced - $80K - $100K. The Advanced option incorporates Allen-Bradley PLC’s and industrial
control apparatus, with Invensys Wonderware In-Touch electronic operator interface with remote access,
trending, recipes batch management with dozens of programmable parameters. The scope of supply for EBA
Advanced can include all the same items covered under EBA Basic, plus the mill house, and interface with the
bottling line. Multiple VFD’s are utilized in this option.
Option 3 – EBA Enterprise -$125K - $250K. This solution offers all the same features as the EBA Advanced
option, but also includes an upgrade to Invensys Wonderware System Platform MES Software. While all the
automation remains the same as EBA Advanced, the interface options to ERP software, production planning,
quality control, energy management monitoring and a variety of other MES based features are utilized.
A list of recipe based programmable parameters are listed in the Table EB1 below:
Table EB1 – Recipe Based Programmable Parameters EBA Advanced
Parameter
Parameter
Parameter
Parameter
Malt weight (feed auger)
Mash Tun water volume
Lauter Tun inlet / outlet valves
Whirlpool exit speed
Mill roll space
Mash Tun hydration time
Lauter Tun cleaning cycle
Nitrogen stripper speed
Mill speed
Mash Tun mash feed out
Kettle temp (jacket, calandria)
Nitrogen stripper vacuum
Malt feed rate
Mash Tun cleaning cycle
Kettle volume
Heat exchanger time, flow rate
Specialty malt feed
Lauter Tun water temp
Hops addition, qty., time, type
Fermentation time
Malt feed order (type)
Lauter Tun water level
Kettle recirculation
Fermentation temp profile
Grist hopper feed auger
Lauter Tun recirc speed
Kettle recirc time
Conditioning time log (rotation)
Grist feed rate (mash tun)
Lauter Tun recirc time
Kettle settling time
Conditioning temp
Mash Tun inlet / outlet valves
Lauter Tun rake speed
Kettle cleaning cycle
Brite time log (rotation)
Mash Tun agitation speed
Lauter Tun rake direction
Kettle vacuum (draft fan)
Brite temp
Mash Tun agitation time
Lauter Tun rake time
Whirlpool inlet speed
Tank inlet / outlet valves
Mash Tun strike water temp
Lauter Tun feed to kettle
Whirlpool settling time
Tank inlet / outlet flow rates
Providence Process Solutions, LLC - vern@prov-ps.com - Cell: 262.770.1292
Enterprise Brew Overview
Enterprise Brew Automation, (EBA) Continued
Table EB2 – EBA’s Three Automation Options Features
Feature
EBA - Classic
EBA - Advanced
EBA - Enterprise
Price
$25K - $40K
$80K – $100K
$125K - $250K
Delivery
4-6 Weeks
6-8 Weeks
12-16 Weeks
Control Zones
All tanks manually
All tanks electronically
Mill room, all tanks, all ancillary
equipment monitoring
PLC
No
Allen-Bradley CompactLogix
Allen-Bradley ControlLogix
# Programmable Parameters
Just tank temp. settings
70 + Tank / recipe related
250 + Enterprise wide.
Operator Interface
Manual pushbuttons
Wonderware In-Touch
Wonderware System Platform
Control Enclosure
NEMA 4X, U/L 508
NEMA 4X, U/L 508
NEMA 4X, U/L 508
Remote Access
No
Desktop, PDA, I-Phone, Web
Desktop, PDA, I-Phone, Web
Data Communications
No
Ethernet
Ethernet
Application Server
No
Dell Optiplex
Dell PowerEdge
Display Size
No
1 @ 19” Display NEMA 4X
2 @ 19” Display NEMA 4X
Motor Control
80% Manual, 20% VFD’s
30% Manual, 70% VFD’s
100% VFD’s
Temperature Control
Manual set point
Elect. Temp. Profile
Elect. Temp. Profile
Level Control
Manual set point
Elect. - Infinitely variable
Elect. - Infinitely variable
Alarming
No
Lights, Horns, LED Display, PDA, Lights, Horns, LED Display, PDA,
I-Phone, E-mail
I-Phone, E-mail
Data Logging
No
Electronic – Unlimited points
Electronic – Unlimited points
Data Base
No
SQL Server
SQL Server
Data Base Size
No
Unlimited
Unlimited
Data Trending
No
Multi-variables - real time
Multi-variables - real time
SOP Monitoring / Alarming
No
No
Electronic
OEE Reporting
No
No
Electronic
Formulation Batching
No
Yes, unlimited
Yes, unlimited
Batch Q.A. Logging
No
Electronic
Electronic
Ingredient Lot Trace
No
Manual LED Display
Automated bar code
ERP Software Integration
No
Yes, via SQL Server
Yes, via SQL Server
Production Scheduling
No
No
Yes, multiple variables
Workflow Modeling
No
No
Yes
Energy Management
No
No
Yes
Maintenance Triggering
No
No
Yes
Electronic with ERP reporting
Electronic with ERP reporting
Liquid Inventory Management No
Providence Process Solutions, LLC - vern@prov-ps.com - Cell: 262.770.1292
Enterprise Brew Overview
Enterprise Brew MES
Overview – Pricing – Application dependent. Manufacturing Execution Systems,
are used in larger operations where highly integrated data communications is a
priority. MES Systems support production scheduling, workflow modeling, overall
equipment effectiveness, quality statistics, SOP Development and adherence,
yield optimization, automated lot traceability and product genealogy, and provide
ERP business software with data that support inventory management, production
cost variance analysis, and order fulfillment metrics.
MES Vs. Control - MES systems do not typically control the plant floor automated processes, but rather rely on
the data created by these plant floor automated systems in order to extract only the data necessary to calculate
and report the operational metrics often unique to each plant.
The EB MES Suite - was designed to support all of these operational metrics and utilizes Invensys –
Wonderware’s System Platform Product. EB MES is priced based on the level of data point integration required
to support the craft brewer’s needs and is part of EBA – Enterprise Edition. The MES Modules are outlined in the
model below and all communicate directly to Microsoft SQL Server Database.
The EB MES Process - An EB MES solution begins with detailed review of all existing plant
data collection systems, database formats, and report schedules. This current state
information is then compared to the operational strategic plan objectives to determine
resource alignment efficiency. Gaps are defined, inefficiencies are red-lined, and a new
future state plant floor to top floor data map is created using one or more of the
modules outlined in the diagram above.
Providence Process Solutions, LLC - vern@prov-ps.com - Cell: 262.770.1292
Enterprise Brew Overview
Enterprise Brew ERP
EB-ERP 1 – Annual Volume = 7,000 BBL’s or less. Price = $2,900. Database – Microsoft Access. Scope = Tank
inventory, batch production make sheet data and Federal Tax forms. Financials = QuickBooks. Annual updates =
Available. Training = < 1 Hour. User Installs – Unlimited per plant. Interoperability = None.
EB-ERP 2 – Annual Volume = >15,000 BBL’s. Price = $20-$30K + Labor. Database = Microsoft SQL Server. Scope
= All inventory, orders management, production reporting, lab. Financials = Microsoft Great Plains. Annual
updates = Yes, under maintenance. User Installs = Server based, variable. Interoperability = Very high. EB-ERP2
supports the following:
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EB-ERP2 Orders Management
Features
Multiple reports by customer / product / territory.
Automatic order holds based on customer credit limits.
On-line inquiry of open and historical customer orders.
FIFO Picking slips and multiple shipping documents.
Date sensitive pricing, promotions, and allowances.
Multiple order templates for each customer / group.
Multiple pricing methods by customer categories.
Multiple ship-to / bill-to locations per order.
Direct integration with Microsoft GP - A/R.
Manual or electronic order entry via EDI.
Optional bar code picking option.
User friendly navigation.
EB-ERP2 Production Reporting
Features
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Formula based automated inventory relief.
Formulas include materials, labor and burden.
Ability to assign production to an order or customer.
Production formulas by batch size.
Manual / automatic entry of produced inventory.
Tracks lot codes of all ingredients and finished goods.
Tracks theoretical versus actual yields per batch.
Statistical database for each product line.
Accommodates Work-in-Process (WIP)
Integrates with SQL Server SCADA.
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EB-ERP2 Inventory Management
Features
Document reasons for inventory transfers and adjustments.
Costing items by standard, last, original, current or average.
User defined Lab characteristics tracked by item / batch.
Audit Trails – date and time stamped and user defined.
Supports multiple warehouses, storage rack locations.
Track product by lot code, pallet number and location.
Sound accounting period cutoffs via “effective dates”.
Supports inventory cycle counting and reporting.
Ability to report lab test results and QA holds.
Minimum order point reporting and quantity.
Manage inventory using 6 units of measure.
On-line inquiry by multiple categories.
Keg deposits and tracking is supported.
EB-ERP2 Microsoft Great Plains
Financials
Microsoft GP integrates directly with Orders Management,
Inventory and Production Reporting for accurate and reliable
production costing, inventory valuations, order fulfillment,
and material procurement activities without requiring
double entries.
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Bank Reconciliation
Accounts Receivable
Accounts Payable
Purchase Order
General Ledger
Fixed Assets
Providence Process Solutions, LLC - vern@prov-ps.com - Cell: 262.770.1292
Enterprise Brew Overview
Enterprise Brew Auxiliary Process Equipment
Overview – Pricing = Application dependent. Adding production capacity typically requires an evaluation of
all existing auxiliary equipment. It is typical that refrigeration, steam, compressed air, and cooler systems
may all need to be upgraded in order to support the increased process capacity demands. Enterprise Brew’s
Auxiliary Process Equipment program assists craft brewers in navigating through these evaluations and
related costs. The resultant system modifications can take many forms from upgrading to replacing existing
systems. EB will manage the entire process from evaluation of existing systems, to engineering incremental
needs, to coordinating proposals and work project management with EB’s preferred business partners.
Some key factors to consider include:
Refrigeration
Systems
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Demand based multi-stage compressor
Packaged or roof top mounted condensing units
Demand based VFD operated glycol pumps
Various piping types and configurations
Installation of all equipment and piping
All fluids, commissioning, training included
Ethernet based electronic controller
All-in-one supports tanks and cooler(s)
Includes all P&ID’s, Valves, instrumentation
Refrigeration
Coolers
Boiler
Systems
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Low or high pressure steam boilers
Conditioning make-up water system
Water recovery system apparatus included
Compatible with multiple fuel sources
Installation included piping and insulation
All fluids, commissioning, training included
Ethernet based electronic controller
All system engineering is included
Includes all P&ID’s, Valves, Instrumentation
Compressed
Air
Providence Process Solutions, LLC - vern@prov-ps.com - Cell: 262.770.1292