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  w  w  w  w 

Seamlessly report production data to Government agencies Trending Batch-to-batch comparisons Accurate material tracking and batch tracing 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. 4

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

Key automation justifications Automation Control Systems

n Brewhouse 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

n Fermentation 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

n Automate the CIP sequence w  w  w  w  w  w 

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

n Scalability 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  w  w  w  w  w 

Pressure and Level sensors / transmitters Flow sensors / transmitters Temperature sensors / transmitters On-Line pH and Conductivity sensors / transmitters Automatic control valves 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  w  w  w  7

Controller configuration program HMI configuration program Reporting and Data Archiving Interface to Business System,

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 Brew Kettles

Fermentation

Heat Exchangers Yeast Propagation Aging & Storage Filtration

CIP System Analytical

Temperature

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Filling/Packaging Line

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 10

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

Fermenting - Primary Fermenter Automation Control Systems Level

Air mass (sterile)

Pressure

Temperature

Mag Flow

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Level / Hydrostatic pressure

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. 16

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 §  §  §  §  17

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

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

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CIP System P & I D

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

Brewhouse CIP Automation Control Systems

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CIP System in the Automation System

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. 25

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

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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.

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 Control Systems

n  Very Common to use MS Excel or MS Access 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