SERVICE

Engineering A Guide to Preventing Leaks CIP Auditor CIP DIY Pasteurizer DIY Restoring drawings 3D scanning

EQUIPMENTS

CIP stations API Schmidt-Bretten SIGMA Plate heat exchangers and components Pasteurizers Blending unit

COMPONENTS

GEA cleaning technology GEA valves GEA pumps GEA centrifuges & separation equipment

MONITORING

QiVisor Monitoring Systems Process optimization
GASTEST EXPERTS CASES BLOG CONTACTS

EN

EN UA PL RU
Contact Us

16.07.2024

Breweries

Monitoring systems for breweries

Every brewer strives for consistent quality of his product. Beer spoilage, poor taste due to non-compliance with the recipe means under-delivery and returns to stock, leading to reputational, financial and legal losses.
 

Why do you need monitoring systems?

Remote monitoring of production processes helps:

  • monitor key parameters around the clock and respond quickly to abnormal situations;
  • objectively see bottlenecks in production and find ways to improve the process;
  • reduce equipment downtime due to emergencies;
  • plan effectively the repair and investment programme based on the actual condition of the equipment
  • to see the places of leaks and losses, to reduce costs for energy and water consumption;
  • receive objective reporting on the state of the brewery.

The customer receives a financial benefit that exceeds the investment in online monitoring of production lines.

Examples:

  • In Viravix’s practice, remote monitoring of production parameters helped to increase the productivity of the fermentation section by 15% without costly upgrades. The system saw that the separation equipment was under-utilised due to the existing process layout.
  • A day’s visit to the brewery by an expert costs around 340 euros in travel expenses. With the implementation of remote production monitoring, he can solve the customer’s problems remotely, without being present at the brewery in person. The system will provide all the data for analysis.
You get an effective tool to ensure consistent product quality and reduce risks from human error.
 
 

What you can monitor in the brewery

Fermentation tanks (CCT)

Monitoring the temperature and pH during the fermentation and filtration processes helps to ensure efficient wort extraction

Boiling

Temperature and volume monitoring ensures that the wort is boiled for the right amount of time to achieve the desired level of flavour and bitterness

Fermentation

Temperature and pressure monitoring makes sure that the yeast works optimally and delivers the required alcohol level

Carbonation

Temperature and carbonation level monitoring helps to monitor the maturation of the beer and guarantee the flavour profile of the recipe

Packaging

Tracking the consistency and quality of the filling process ensures that the requirements of the finished product are met

The list of applications for remote monitoring of production line processes in a brewery is open. The installation and configuration of the system depends on the customer’s needs. You can also monitor pasteurisation, CIP washing, energy and water consumption.

Monitor your brewery 24/7 from anywhere in the world where the internet is available.

Examples of monitoring systems for different equipment

QiVisor

 

What the system can do:

  1. Can control energy and water consumption, pasteurisation, CIP washing.
  2. Suitable for CKTs, pipelines.
  3. Monitors the status of events on the production line.
  4. Shows process performance history for any period (hour, day, week, year).
  5. Analysis of the efficiency (OEE) and productivity of the line.
  6. Displays reports in Excel format.

Developer: META SYSTEMS LLC

Features

Keeps track of water, steam and electricity consumption. Additional utilities can be added.

  1. Monitors capacity equipment load.
  2. Monitors line events and downtime.
  3. Monitors CIP washing of equipment.
  4. Monitors the pasteurisation process.

Advantages

  1. Ability to add parameters and events.
  2. Easy set-up, without the need for external specialists.
  3. User training and video tutorials.
  4. A cloud-based product that does not require servers, workstations.

Safe to use

  1. Data is stored in the cloud in encrypted form – Encryption-at-Rest.
  2. The information is sent over a secure HTTPS connection.
  3. Backups are made every day.

Koeebox

 

What the system can do:

  1. Monitors power consumption; operating time; temperature; vibration level; pressure level; weight.
  2. Sends warnings when parameters are outside specified limits.
  3. Logs the operating mode readings.

Developer: Koeebox

Features

Measures:

  • power consumption;
  • operating time;
  • temperature;
  • vibration level;
  • mass;
  • pressure.
  1. Recognises operating modes.
  2. Records energy consumption.
  3. Displays current process status.
  4. Tracks operating time.
  5. Sends instant notification.

Advantages

  1. Requires no infrastructure and no dedicated staff.
  2. Can be installed in 15 minutes.
  3. Works on any equipment where electricity is available

 

Safe to use

  1. Cloud storage.
  2. It is up to the client to decide to whom they give access to the data.

Capabilities of PLC-Analyzer:

 

  1. Monitors PLCs from various manufacturers and analyses their data to identify potential problems and optimise the performance of the hardware and software system.
  2. Simulates PLCs for testing and troubleshooting.

Reference. PLC – programmable logic controller. This is the name given to industrial computers for factory automation.

Developer: AUTEM— PLC-ANALYZER pro 6 simplifies the acquisition, presentation and evaluation of PLC signals such as input, output, flags, timer, counter, data block dat.

 

Features

  1. Diagnoses faults.
  2. Eliminates random errors.
  3. Optimises cycle time.
  4. Keeps a permanent record of measured parameters.
  5. Monitors the status of the PLC in real time.

Advantages

  1. The Virtual HMI module assists in accident investigation.
  2. The subsequent visualisation of the HMI based on the recorded process data facilitates the detection of possible operating errors.
  3. The HMI visualisation can also take place live during recording.

Safe to use

  1. Compliant with TPM/OEE, EU Machinery Directive.
  2. Stored on workstations.

Clarify

 

Features:

  1. The main purpose is to easily visualise and organise data.
  2. Monitors temperature, pressure, flow and pH.
  3. Provides real-time data visualisation and reporting.
  4. Monitors filling lines to ensure efficient and accurate filling of containers.

 

Developer: Clarify

Features

Integrates and visualises data from different sources.
Suitable for the systematisation and analysis of the performance of industrial equipment and utility systems, PLC systems and SCADA systems.

Advantages

  1. User-friendly interface for data integration, visualisation and organisation.
  2. Streaming timeline technology for fast navigation.
  3. Search and filter functions.
  4. Time selector to get statistics and comparative analysis.
  5. Addition of multimedia: videos and photos.
  6. Search and view previous transactions.
  7. Proprietary mobile app.
  8. Quick data export.
  9. @-remembering function for collaborative work.
  10. Support for Node-RED, OPC UA, Azure IoT, MQTT, Ignition and Google Sheets add-on.

Safe to use

The list of users and their access is determined by the customer.

A hardware and software system consists of sensors, controllers and software with a user interface. The detectors can be installed on almost any equipment, and the setup of the system is similar to that of Wi-Fi.