CIP Automation & Monitoring for Breweries

March 17, 2016

Adam Friedler

Agenda

• Automation Opportunities

• Automation for CIP monitoring & optimisation

• Case Histories

• Questions

GOAL OF AUTOMATION IS UNCOVERING OPPORTUNITIES

CELLAR

BREWHOUSE

BOTTLING HALL

Bottle washer

Pasteurizer

Filler

Filter

Crate washer

Filtration

UTILITIES

for CIP

OngoingOperational

Pressures

TroubleshootingQuality Issues

LaborAvailability

Balancing &Prioritizing

Activities

DataOverload

StandardizingProcesses

BREWERIES ARE IN CONSTANT MOTION

CIP SIGNIFICANTLY IMPACTS OPERATIONS AND IS DIRECTLY RELATED TO CORPORATE DRIVERS

BRAND PROTECTIONProduct Safety & Quality

OPERATIONAL EFFICIENCYCleaning TimeOptimization

SUSTAINABILITYWater Savings

Energy ReductionWater Treatment

COMPLIANCE WITH REGULATIONS

Validation Support

PRODUCT INNOVATIONNew ProductC&S Support

Next step on our CIP evolution

1957

First CIP single use

1973

First spray ball

80s – 90s

Sanitizer innovation (Peracids)

2013

3DT CIP

CIP LEADERSHIP JOURNEY

WHAT IS 3D TRASARTM CIP?

PlantInstruments

Advanced Sensors

Proprietary Chemistry

Ecolab CIP Experts

Process Visibility & Action

3D TRASAR CIP is a constant CIP optimization program that uses advanced sensors that monitor traced chemistry providing process visibility with actionable data supported by Ecolab service and

industry leading expertise.

Secure analytical and reporting portal

Secure web access to customized monitoring and analysis portal

HOW DOES IT WORK?

OPC ServerHistorian Database

I/O and MESChemistry

Sensors Valves/Pumps Analog

Signals

Meters/SensorsDigital Signals

Local Server(SmartBox)

PLC Network

for CIP

WHAT ARE THE OUTCOMES?

Monitors CIP systems 24/7/365, safeguarding CIP quality, total cost and process optimization by:

Establishingconsistent CIPsfor eachobject/circuit

Tracking each CIPagainst itsoptimal CIPprofile

Flagging deviationsthat may impactproduct qualityand efficiencies

Identifyingoptimizationfor quality & cost

Providing benchmarkperformance toSOP’s & betweensystems

for CIP

WHAT DOES THE OUTPUT LOOK LIKE?

Resource Consumption1

for CIP

Resource Consumption1 Change to last 7 or last 28 daysView a different

facility

View 10-day trends for each resource

Electricity consumption in last 24 hours

Electricity consumption vs. the previous 24 hours

WHAT DOES THE OUTPUT LOOK LIKE?

WHAT DOES THE OUTPUT LOOK LIKE?

Top Consuming Washes2

Drill down to understand why cost is so high

What equipment is using the most thermal resources?

Quick links to view CIP run report and chart

WHAT DOES THE OUTPUT LOOK LIKE?

Top Consuming Washes2

Wash Summary and Identifying Deviations3

WHAT DOES THE OUTPUT LOOK LIKE?

Drill down for Detail on the Deviation

What Deviation is occurring?

Quick links to view CIP run report and chart

Do I Need to Know Immediately?

Wash Summary and Identifying Deviations3

WHAT DOES THE OUTPUT LOOK LIKE?

European Brewer Case Study

CIP automation helped a brewer achieve exceptional hygiene procedures while realisingsignificant operational savings.

Ecolab’s 3D TRASAR CIP Technology provided a major European brewer with the technology it needed to achieve its “Golden Hygiene Plan” while reducing costs and driving continuous improvement.

REDUCED ENERGY USAGE

SAVINGSSAVEDSAVED

OPERATIONAL EFFICIENCY

approx.

$4,900

pa

Over

$110K

REDUCED WATER CONSUMPTION FOR

STERILIZATION

TOTAL ECONOMIC

BENEFIT

approx.

$42,700

pa

(After Two Months)

for CIP

CASE STUDIES

High Temperatures

Situation:• 3DTRASAR for CIP shows that temperatures for caustic and

sterilization cycles consistently exceed the stated set points• Caustic: feed temp 85C, return temp 75C• Sterilization: feed temp 92C, return temp 80C

Opportunity:

• Reduce temperatures to optimal range

Solution:

• Optimized temperature programming to save energy

• Established tighter range for exception reports to monitor the change

Caustic cycle showing a return temperature of 90.70C should be no more than 750C

Sterilisation cycle showing a return temperature of 94.70C should be no more than 800C

3D TRASAR™ CIP Analysis: • Sanitizer pump fired, but no

sanitiser signal detected indicating several possible scenarios (empty drum, sensor not working, cracked tubing etc)

• This occurred for a number of washes before resolution

• 2nd chart demonstrates 3D TRASAR™ sanitiser signal verified

• Ability to set sanitizer concentration Exceptions and Notifications

No Sanitiser Signal

3DT Sanitiser Signal Verification

Pumpsignal activated

No traced sanitiser signal

Pumpsignal activated

Traced sanitisersignal

CASE STUDIES

Hot Water not Recirculated

SITUATION:

OPPORTUNITY:

• During sterilization of yeast storage vessels, 3D TRASAR for CIP found that hot water was pumped to drain and not recirculated

• 141 hl per wash sent to drain

• Recirculate hot water to capture savings

• Recommended improvements to water management in the vessel to ensure correct flow rates achieved

• Improvements enabled the hot water to be recirculated around the vessel

• Alternative solution: replace hot water with PAA

SOLUTION:

Estimated annual savings:

$30,714

$46,750Assuming 48 cleans/week

CASE STUDIES

Safety & Energy Cost Avoidance

SITUATION:

OPPORTUNITY:

• High start-up temperatures during all CIP cycles

• Avoid early equipment replacement

• Save energy

• Prevent scalding incident

• Account Manager confirmed high temperatures at source

• Plant to replace leaking valve

• On going notification to prevent future incident

SOLUTION:Supply Temperature

CIP Inactive CIP Active

Return Temperature

Fact Summary:

$7,000

$14,000

$15,000

Total: $36,000

CASE STUDIES

Product Quality issue IDENTIFIED

SITUATION:

OPPORTUNITY:

• Investigation of wash water consumption deviation found operator skipped the pre-rinse on the wash of Tank 8.

• Carry over of heavy soils into wash will prevent effective wash

• SSOP Compliance

• Supervisor trained Sunday operator with Wash Summaries.

• New Exception for extended rinse phase AND low volume could indicate improper CIP connections.

SOLUTION:

Training

‘"Rinse" Phase, between steps 3 and 5 for this object was less than 4 minutes or under 400 gallons…’3D TRASARTM for CIP Diagnostics System Notification

3D TRASAR(TM) for CIP Diagnostics System Notification:

CASE STUDIES

3 Burst Rinses Skipped

Proper Rinsing

CASE STUDIES

CIP automation helped dairy achieve

consistent Clean-in-Place performance

— and consistently high quality product

REDUCED WATER CONSUMPTION FOR

CLEANING

REDUCED CLEANING TIME

SAVEDCONSERVED

963,750

gallons 1,295

hours

REDUCED CHEMISTRY FOR

CLEANING

CONSERVED

3,000

gallons

• Generally 10 to 20% reductions in CIP operating costs seen.

• Results vary based on current state of CIP system and SSOP compliance.

CASE STUDIES

Identify equipment malfunctions; protect

assets from unneeded wear; direct PM

resources to problem areas

Real-timevisibility to plant

SSOP conformance; automatically track

improvement over time; reduced risk of

quality incidents

Real-time visibility of consumption metrics;

trending reports over time; identification

of largest resource drains

SustainabilityCorporateQuality

Engineering & Maintenance

Plant QualityAssurance

Production &Operations

Manage and reduce CIP time; reduce risk

of product loss due to improper CIP;

data driven projects to reduce costs

Visibility to leadingindicators of product

quality; manage exceptionsto SSOP; faster root

cause analysis

CONSISTENCY & OPTIMAL SYSTEM PERFORMANCE

SUMMARY

Thank You.

Questions?