Modernisation of a pasteurisation unit for Umanpivo

In this project, Viravix Engineering’s experts automated and revamped a second-hand, converted pasteuriser made in Germany. We were working on equipment for which the customer did not have up-to-date design and operational documentation. Even taking into account the cost of our services, the customer spent three times less than he would have paid for a new pasteurisation unit.

Customer

Our client is a large brewery “Umanpivo” in the Cherkasy region of Ukraine. The brewery was founded in 1878.

Since 2008, Umanpivo has cooperated with brewers from Germany and purchased their equipment. Since then the brewery has modernised its line with the installation of cylindrical-conical tanks (CTC) and a CIP washing station. Viravix experts have been involved in a number of projects for Umanpivo.

The client’s brewery produces several types of beer – filtered and unfiltered, ciders, lemonades and kvass.

Problem

The customer had installed a PET filling line and purchased a second-hand inline pasteuriser from Germany. The equipment he had purchased was in a poor state of repair and he wanted to integrate it into an existing production facility and integrate it into his automation system.

The pasteuriser was upgraded after manufacture, but no documentation of this was kept. The Viravix engineers had to put the unit into operation without a PID, a spare parts list and an up-to-date wiring diagram.

Tasks

The customer wanted:

• To modernise and automate an inoperative pasteuriser. To do this, the pasteuriser had to be assembled with the components that were available.
• The pasteuriser was to be set up for beer, cider, lemonades and kvass.
• To ensure the exchange of signals from the heat treatment unit with the filtration department, CIP station and PET and glass bottling lines.
• Use a pasteurizer for each line individually as well as for the operation of two lines at the same time.

In addition, a remote monitoring system with two years of data archiving had to be installed on the equipment.

Background. Remote monitoring systems are part of the Industrial Internet of Things (IoT). They consist of sensors connected to equipment, controllers and operating software. The systems enable remote data acquisition of process parameters and control of equipment operating modes without personal presence in production.

Viravix Engineering uses in-house developed remote monitoring systems. We invented and tested them during the covid pandemic when, due to restrictions, our engineers were unable to visit customer sites in person.

Solution

The customer did not have up-to-date PID drawings for the pasteuriser they had purchased, so we assembled the line design in the existing configuration. We had to simulate past plant situations to see what needed to be changed to suit the customer’s existing requirements.

What we did:

• Developed a new PID scheme for the inline pasteuriser, taking into account the operating conditions and customer requirements for the pasteurisation temperature for the end products and the capacity of the plant.
• Dismantled equipment and pipework that were not involved in the heat treatment plant.
• Draw up a bill of quantities for the required components and organise their purchase.
• Developed a schedule for mechanical and electrical installation work.
• Design of signal exchange between pasteurizer and filling lines, filtration department, CIP-station for process automation.
• Additional necessary equipment was installed and new piping was installed. Uninterruptible power supply in the electrical cabinet.
• Electrical installation according to new PID scheme. New software was written.
• Performed dry and hydraulic tests to verify equipment operation. Set up signal exchange and communication between pasteurizer and prefab, filling units, CIP station. Conducted test runs on water and subsequent tests on different products, varying loads and plant capacity.
• Installed remote monitoring system and trained customer staff on its operation.
• Reference. KHS, Simens, Grundfos equipment was used in the project.

Result

The brewery received a fully automated pasteurisation unit to meet its production requirements. In fact, Viravix engineers gave a “second life” to the working equipment by carrying out a number of improvements.

For the purchase and modernisation of a second-hand pasteuriser the customer paid three times less than he would have paid for the purchase and set-up of a new pasteuriser. And that’s including the cost of our services.

Additionally, Umanpivo received a remote monitoring system which helps control the technological process 24/7 from any place in the world where internet is available.

The use of remote technology facilitates service. Our engineers can always remotely help solve an abnormal situation at a pasteuriser without having to travel to the site – only based on data from the monitoring system. This saves the customer time and money.