While many large breweries are still hesitant, the family-owned brewery in Middle Franconia is already setting new standards. Thanks to a smart cloud solution, all technical systems at Pyraser have been digitized, workflows simplified and energy saved.
The automation landscape of many breweries is characterized by heterogeneous standalone systems, often combined with handwritten data recording. Monitoring production processes and utility supplies is time-consuming, and optimization potential remains hidden due to a lack of data collection. This is not the case in Thalmässing, Middle Franconia, where all technical systems are digitally monitored. Of course, the brewery, which employs 80 people, did not start from scratch. However, the existing HMI systems were limited to their respective applications and did not offer the capabilities of a modern cloud solution. Therefore, the existing infrastructure was retained and the AnyViz cloud solution was introduced: The control systems for refrigeration units, the pasteurizer and the bottling plant were connected in no time. Where necessary, affordable controllers were retrofitted. Within just a few months, 21 systems were connected that had previously operated as standalone solutions. In addition to the production line, building technology, combined heat and power plants (CHP), the photovoltaic system, wells and other installations were also integrated into the central monitoring system.
Utility Supply at a Glance
Various utilities are used in the brewery: refrigeration, steam, water, compressed air, nitrogen and electricity. All of these utilities must be reliably available to ensure smooth brewery operations. Consequently, the utility supply dashboard has become an important tool for the brewmaster. It provides a clear, real-time overview of all operating conditions and key figures. In addition, all relevant faults and warnings are displayed, allowing action to be taken before a system shutdown occurs.
Remote Control of the Brewery
The working week of brewmaster Achim Sauerhammer begins at 3 a.m. on Sunday night. This is when the bottle washer needs to be switched on. If it has not fully heated up by 6 a.m., production has to be delayed. Previously, the brewmaster had to drive to the brewery to take care of this. Today, the process runs automatically. If an error occurs during the automated startup of the system, the brewmaster is immediately alerted and can intervene remotely. As a result, both the brewmaster and the machine operators need to travel to the brewery less frequently.
No More Manual Record-Keeping
As in any production facility, data must be collected and properly documented. This includes water levels in the company’s own well, brewing temperatures and inventory levels. Thanks to complete digitalization, all this information is automatically recorded and stored redundantly in the cloud. Authorized employees have access to the data. For example, the laboratory can access operational data in real time. The district administration, on the other hand, automatically receives generated reports containing the well data. All visualizations, dashboards and reports can be created easily using drag and drop. This can be accomplished quickly without any technical expertise.
Easy Analysis of Operational Data
Thanks to cross-departmental operational data recording, entirely new opportunities have emerged. Potential savings in the compressed air supply were identified quickly, resulting in savings of 10 MWh within just four weeks. The convenient data analysis tools also support troubleshooting. In particular, problems relating to the CHP units and their associated heat management can be quickly diagnosed and resolved. In this way, AnyViz helps reduce energy costs, minimize faults and increase operational reliability.
Rapid Response in the Event of a Fault
Every brewery knows the consequences of important components, such as cooling systems, failing unnoticed. The AnyViz alarm solution enables notifications via email, SMS, push notifications or voice calls. This allows several employees to be informed simultaneously in the event of a fault. A delay can be configured for each notification recipient, creating an alarm escalation chain that only ends once the alarm has been acknowledged.
Increasing the Share of Renewable Energy
As a responsible family-owned business, the brewery is committed to renewable energy. To this end, photovoltaic systems with a total capacity of 500 kWp have been installed. In addition, two CHP units generate electricity and heat using CH4 from wastewater treatment and the adjacent landfill site. As early as 2021, the brewery achieved a renewable energy share of 36%. This share is now set to increase significantly. The cloud solution helps optimize processes to ensure that self-generated energy is used as efficiently as possible and the share of externally sourced energy is reduced to a minimum.
Hardly Any New Equipment Required
Many businesses are reluctant to undertake extensive digitalization projects. Too often, they have heard about high investments, escalating costs and insufficient returns. Pyraser has demonstrated that this does not necessarily have to be the case. First, the free Cloud Adapter Application, which serves as a bridge between local technology and the AnyViz Cloud, was installed on an existing server. From then on, all Ethernet-based systems, such as Siemens controllers and gas analyzers, could be connected. However, the brewery also operates a number of other components that are not yet network-enabled. Replacing these with modern components would involve considerable expense while initially offering little added value. Therefore, a total of 27 meters, controllers and actuators were connected via a two-wire bus. Apart from the affordable cabling, no additional investments were required. Even the 25-year-old nitrogen generators and the equally old compressed air compressor could be digitally networked in this way.
Supporting Different Communication Protocols
One of the challenges when digitizing existing infrastructure is the wide variety of communication protocols. Different standards are used depending on the manufacturer and the age of the equipment. The cloud platform used by the family-owned brewery supports seven automation protocols commonly found across various technical systems. At Pyraser, most components were connected using Modbus TCP, Modbus RTU and Siemens TCP. However, two additional integration methods were used for the CHP units. Using the VNC protocol, the screen contents of the control panels of both CHP units are mirrored to the cloud. Since mouse movements and keyboard inputs are also transmitted, the systems can be viewed and operated from any location. In addition, a webcam was installed. Its live video feed is securely transmitted to the cloud solution via the HTTP protocol. This means that, alongside operational data, both the control panel interfaces and live video images are available.
Connecting Systems Over a Distance of 1,100 Meters
Digitizing the well system, located more than 1,100 meters away, initially appeared challenging. Only an unshielded telephone cable had been installed to transmit digital signals. However, meter readings, water levels and other analog signals also needed to be transmitted. By using signal amplifiers, a Modbus RTU connection was established over the existing cable. This reliably exchanges data and can be expanded as required. This demonstrates that even seemingly outdated two-wire technology can still be useful for digitalization.
Reducing Peak Loads
Comprehensive energy management is not only about improving energy efficiency. Reducing peak loads also plays an important role, as it can lower the capacity charges billed by the electricity supplier. Peak loads become particularly relevant when they approach the capacity limit of the locally installed transformer. Pyraser therefore needs to ensure that the maximum capacity of 350 kW is not exceeded. Only through comprehensive data collection and meaningful visualization can the causes of peak loads be identified and avoided. It was quickly discovered that operating several compressed air compressors simultaneously was causing high peak loads. This is now being avoided.
Security Comes First
No digitalization without security! It goes without saying that all data streams outside the field level are encrypted and that the company’s firewall continues to block incoming connections. Where different groups of employees work together, user management is also essential. It restricts access to the information and functions required by each user and enables secure multi-factor authentication. The SaaS (Software-as-a-Service) provider AnyViz takes care of security updates, maintenance and backups. This reduces the workload for the IT department and ensures that the brewery always has access to up-to-date software.
Easy to Expand
Following the introduction of the cloud system by automation expert Richard Bernreuther, further expansion is now carried out by the brewery’s own technical staff. When asked how long it takes to commission a new data point, plant electrician Stefan Neuhofer gives a short and concise answer: “5 minutes.” The ease of expansion makes AnyViz a tool that can be used across every technical department. The possibilities for connecting a wide variety of technical equipment are extensive. AnyViz will also be used for visualization, monitoring and remote operation in the newly planned local district heating network and the brewery’s own wastewater treatment plant.
Conclusion
Digitalization projects can be implemented very cost-effectively using a modern cloud solution such as AnyViz. The existing infrastructure continues to be used and is gradually connected to the cloud, creating a network of previously isolated individual components. Data collection and analysis quickly reveal deviations and areas with significant savings potential. By connecting IT and OT, all departments always have access to up-to-date information – without the need for paperwork.