Brewery & CIP Automation

Systems

Tim Rose
Western States Controls

Ed Montgomery
Siemens Industry

October 9, 2010
 MBAA District NW Fall Meeting October 8th & 9th, 2010

Automation
Control Systems

Thank you for the invitation!

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Automation
Control Systems

What we will cover today:

Why Automate?
Automation Justifications
Anatomy of a System
Architectures, examples
Hints for Success

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Why Automate?
Automation
Control Systems
n Better control and yield
n More consistent product quality
n Reduced energy usage
n Reduced batch time by increasing equipment utilization
w Schedule batches based on sales and equipment availability

n Reduce labor costs

n Monitor and record variable costs
n Better data collection and reporting
w Seamlessly report production data to Government agencies
w Trending
w Batch-to-batch comparisons
w Accurate material tracking and batch tracing
w Manually collected data can be expensive and inaccurate

n Remote control and information available

w Interface brewery with the web to provide data when out of the office.
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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Key automation justifications

Automation
Control Systems
nBrewhouse Automation
w Expands the flexibility of your process to help you create new
recipes, modify existing recipes and try new products
w Optimizes the operation of your brewhouse to produce more
brews in a day

nFermentation Control
w More Consistent batches with temperature Profiles set
automatically.
w No need to adjust temperatures during the off hours
w Trend data analysis

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Key automation justifications

Automation
Control Systems

nAutomate the CIP sequence

w Production downtime between brews is minimized
w Water consumption is reduced Green Initiatives
w Data Logging and reports for QA / QC requirements
w Reduce waste
w Personnel safety
w Regulatory requirements

nScalability
w Start with what you need and can justify

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Anatomy of an automation system

Automation
Control Systems
n Field devices You can only control what you measure
w Pressure and Level sensors / transmitters
w Flow sensors / transmitters
w Temperature sensors / transmitters
w On-Line pH and Conductivity sensors / transmitters
w Automatic control valves
w Drives and motors

n Controller and I/O

w Distributed Control System (DCS) or Programmable Logic Controller
(PLC)
w Input and output cards (I/O)

n HMI - Enclosure or Control Room

w Human Machine Interface (HMI).Where? How many?

n Application Software
w Controller configuration program
w HMI configuration program
w Reporting and Data Archiving
w Interface to Business System,
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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Instrumentation
The most critical aspect of any control system!
Level
Automation
Control Systems
Flow

Pressure
Brewhouse
Mashing
Temperature
Lautering

Fermentation Brew Kettles

Heat Exchangers
Yeast
Propagation
Aging &
Storage

Filtration

CIP System

Analytical

Temperature

Filling/Packaging
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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Most Critical Measuring & Control Points

Automation
Control Systems
Temperatures, Pressure, Level, Flow

Raw materials supply

Quantities

Water quantities/qualities

Mash profile

Lauter tun cycle time

Brew kettle boil profile

Yeast temperatures

Yeast pitching

Fermentation temperature control

Batch records for data analysis

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Brewhouse Lauter Tun

Automation
Control Systems

Differential pressure
measurement
Sparge water flow

Level

Temperature
Vorlauf Flow

Wort mass, Plato and total extract

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Fermenting - Primary Fermenter

Automation
Control Systems
Level

Air mass (sterile)

Pressure

Temperature

Mag Flow

Level / Hydrostatic pressure

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Fermentation tanks
Automation
Control Systems

Filling level
Switch
Temperature

Excess pressure

Temperature

Filling level
Switch

Filling level
hydrostatic

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Basic CIP Systems

Automation
Control Systems

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Craft Brewing Automation Systems

Questions?
 MBAA District NW Fall Meeting October 8th & 9th, 2010

Brewhouse CIP Facilities

Automation
Control Systems

functions:
vessel cleaning
pipe cleaning

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

CIP Systems overview

Automation
Control Systems

n Cleaning-In-Place (CIP) are systems designed for automatic

cleaning and disinfecting without having to disassemble major
portions of the process

n Automatic CIP systems must include the proper hardware

that can be cleaned in place without disassembly and must
also provide process separation guarantees to ensure
that the brewing process and the CIP solutions do not
mix.

n A properly engineered automated CIP system will allow

cleaning to be carried out in one piece of equipment when
the other processes are still in production using high end
measuring and control components.

n The fully automatic CIP system optimizes the equipment

utilization while you are able to adhere to the proper
sanitation requirements and documentation of the results.
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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Cleaning in Place (CIP)

Automation
Control Systems

A well designed CIP control system can be

expanded to add programs as equipment is
added without additional investment.

Different CIP-programs for different equipment

Brewhouse vessel CIP
Wort line CIP
Filter CIP
Filler CIP
CIP of CIP-Vessels

Different cleaning media

Water (fresh water, recycled water for pre cleaning)
Acid
Caustic
Disinfection agents

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Basic CIP Automation System

Automation
Control Systems

Dedicated to CIP System

Controlled by a stand alone PLC/HMI Panel that requires the

brewer to operate the production equipment manually to
ensure proper sanitation.

Oftentimes these systems will require that the brewery be

shut down during sanitation as it is too difficult to ensure that
the CIP and the Process will not mix.

Usually without feedback to the rest of the brewery.

You can connect them to the plant system in the future

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Fully Integrated CIP Systems

Automation
Control Systems
n Plant Integrated systems:

One Automation System for your production and CIP needs.

The Brewer can schedule CIP Batches as well as
production batches on the same system.

Custom developed to meet your specific breweries needs.

Can trace what has and what has not been cleaned and you
can schedule CIP recipes for pieces of equipment (such as a
Mash Cooker) or whole production lines (such as the entire
brewery).

Your brewery automation system can actually hold up

batches until the sanitation is guaranteed and documented.

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Fully Integrated CIP Systems

Automation
Control Systems
CIP System P & I D

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Brewhouse CIP
Automation
Control Systems CIP System in the Automation System

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

CIP Plant (example)

Automation
Control Systems

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Craft Brewing Automation Systems

Questions?
Control System Architectures
 MBAA District NW Fall Meeting October 8th & 9th, 2010

Systems for the different types for breweries

Automation
Control Systems
Micro Regional Large Breweries

Be sure your system is Scalable to meet your

current and future needs without re-investing
in a system.
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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Typical Entry Level Systems Microbrewery

Automation
Control Systems

Everything in one Enclosure;

Controller, I/O and HMI

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Typical Mid-Size Systems Small Craft Brewery

Automation
Control Systems

HMI / EWS

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Controller / IO
 MBAA District NW Fall Meeting October 8th & 9th, 2010

Typical Larger Systems Regional Brewery

Automation
Control Systems

Dedicated Control Room

Multiple HMI
Multiple Control & IO Cabinets

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Example Automation System views
 MBAA District NW Fall Meeting October 8th & 9th, 2010

Lauter Tun HMI Representation

Automation
Control Systems

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Fermenting Temperature Control

Automation
Control Systems
n Glycol and Fermentation Temperature
w A typical Craft brewer uses less expensive ON/OFF final control
elements therefore you must use a control algorithm optimized
for this type of control.
w A Profile is very useful as it does not require the brewer to
constantly maintain and control the setpoints.

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Recipes/Parameters and Monitoring

Automation
Control Systems

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Trending and Data Analysis

Automation
Control Systems

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Brew Report Example

Automation
Control Systems

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Production scheduling for the Brewhouse

Automation
Control Systems

Definition brewing orders

Definition of CIP orders

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

BATCH Reports
Automation n Very Common to use MS Excel or MS Access
Control Systems

n Analyze Batches and recipe element parameters

n Trend analysis within

batch context

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 MBAA District NW Fall Meeting October 8th & 9th, 2010

Hints to make your automation a success

Automation
Control Systems

n Automate what you can afford today but do not lose sight of
your vision in the future

n Buy a system that is scalable and meets your needs today

and can grown with you in the future

n Start simple, understand that, move on to more complex

problems.

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Craft Brewing Control Systems

THE END