introducing automation getting started fv control by sara ... · share your experiences today...
TRANSCRIPT
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Introducing automationGetting started FV control
By Sara Nichols
share your experiences today #BevExpo2016
AgendaSiemens – Brewing HistoryAutomation – Is it only for Large Brewery’sTypes of ManufacturingControlling / Automating the Brewing process
HardwiredAutomation PLC / SCADADedicated Brewing Solutions
Staring SmallFV AutomationMeasurement / FlowOther consideration
Dedicated Brewing solutionsConcluding considerations
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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
Simply, Siemens has been associatedwith Brewing for a long time
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Of course It's not ... Has Brewing Changed over the last 300 years?
Not reallyHas technology changed?
Yes and the rate of change is speeding upHas 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?
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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Process Instrumentation ...
If you can’t measure it, you can’t control it!
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Brewing is a Process – Automation OptionsSo we’ve establish that the Brew House is a Process – 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
Automation - Temperature Control Brew House Fermentation
For this explanation we will focus on the control of fermentation attemperation
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Discrete Control Pro’s / Con’sPro’s
It’s simpleYou don’t need to be an engineer to fitLow cost?You can easily see & change the set point
Con’sIt’s based in the Brew House so can only be viewed in the Brew HouseIt can’t be viewed or managed remotely Trending and storing values is an additional investment, an add onCost, expensive to maintain?Fermentation profiles ..?
Automation - Temperature Control Brew House Fermentation
Where to start?We think Fermentation / AttemperationWhy?Feedback from UK BrewersIt happens over several daysYou can’t be there all the time to tweak the chillingThis part of the process can affect your marriage!Yeast likes stability not oscillation
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FV Automation Pro’s / Con’sCon’s
It needs programmingCost ..?It has to be installed ..?
Pro’sIt’s can be viewed from anywhereIt’s can be control from anywhere (with the obvious safety considerations)It can store variables (200) to an SD Card that can be down loaded to a PCCost?Fermentation profiles ..?iOS / Android app support
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Common Question – Controlling from SG ReadingCan it be done? Yes
Technology typesTuning Fork - E&HOptical - SigristIn tank submersible transmitters
Is it viable for small brewing companies? Probably notWhy? What are the challenges
Cost , set up, calibration, cleaning & maintenanceThe science coupled with product variability makes this a difficult nut to crack, plus
The instrument The hole in the tankAdditional CIP considerationsTechnical know how to maintain accuracy
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Other considerationBe clear about the problem you are solving & the constraintsPrograms can now be developed into function block – I’ll explainInstallation is no different to a stand alone control unitIt can be supported remotelyIt can be developed / grown to cover HLT temperature, liquor measurements, flow, CIP ...If you grow even further you retain the investment as it can build into bigger systemsYou can grow your investment in bite size chunksYou can use the system to start to record some manual entries e.g. SG sample valuesBut most importantly ......
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Product qualityConsistent repeatable quality across the fermentation process & seasonPrioritisation of FV’sStable temperature control for your yeastEasy storage and management of fermentation values for:
HMRCYour own use
You can build your automation slowly
Temperature Control – Dedicated Brewery Solution
Route C
ontrol
Are a comprehensive process control system for brewing industryHave 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 effortsDelivers powerful recipe control as well as an efficient route controlAllows for software modifications during production with extremely short turnaround timesEmbeds event management and process history
Process
Control
Trendin
g
Test
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The Eternal Brewing TriangleExtract Efficiency
Wort QualityCycle Time
Process Instrumentation ...
Will probably be the same or very similar whatever the control methodology
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Control Process Options pros and consHardwired
An electrician can fault findProcess is typically manualCan start very small and make it up as you goOften considered the cheapest optionThe process is typically dependent on human input management and over-seeing totally on peopleAny 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 / understandingIncludes many of the library objects found in batch applicationsCan easily incorporate alarms and historyPotentially needs to be modified with recipe changesCan be used to collect necessary process information to satisfy for regulatory complianceRequires support from a skilled person
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Control Process Options pros and consDedicated 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 basedThe 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 inGives agility & flexibility to the Brewhouse / New Product Introductions / Seasonal variations Provides robust process control to deliver repeatability and optimised use of raw materialsRequires a more specialist skill set to deliver solutionCaptures data for tracking & tracing, optimizing and regulatory complianceCaptures data to support quantity control and associated laboratory requirementsIs programmed in function block
Retro-fitting a Batch solution means starting again
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Commercial realitiesEngineering resource is becoming harder to find?How to support and maintain?Remote access and visibility?Art or science?Increasing record keeping requirements from ‘off trade’Automation comes at a cost?Implementing the right automation delivers value
- YES
End User
Automation Supplier
Solution Provider
Consultant
it’s not magic Or is it?