Domain-specific brewery process control.

The ABB Ability™ BeerMaker intelligent process control solution just launched will further support breweries in their operational efficiency through digital transformation. ABB’s brewmaster, who has the notable achievement of qualifications from Technical University of Munich in Weihenstephan (D), devised the new package alongside a team with deep process knowhow.

“Our new solution is from our own ABB brewmaster for brewmasters and truly has domain-specific knowledge embedded as well as ABB’s expertise from years in this field,” said Marcello Gulinelli, Global Head of Food and Beverage, Process Automation, ABB.

It will benefit beermakers seeking to optimize their processes, reduce their impacts on water and energy resources and meet consumer demand for more sustainably crafted drinks. The new solution is based on the ABB Ability™ System 800xA® distributed control system and will help brewers improve process quality, achieve high engineering and operator efficiency, enhance safety and boost plant productivity. It has been made available to ABB’s end customers and channel partners.

As part of its launch, ABB Ability BeerMaker will be presented at this year’s drinktec, the world’s leading beverage and liquid food trade fair, held in Munich from September 12 to 16. The timing of the event coincides with the city’s Oktoberfest, which returns after a two-year break due to COVID-19 and runs from September 17 to October 3.

The process automation solution comprises a technological package including a control system with batch functionality following the worldwide S88 standard and a digital twin to simulate new recipes. Crafted and tested with brewing knowledge from ABB’s brewmaster, it can be adapted for each customer using a variety of parameters.

Ready-made and tested templates and objects bring a high level of automation and intelligence of plant functions into operators’ hands. There is a prepared inventory for queue handling, diagnostics and comprehensive cleaning in place (CIP) support.

Designed to meet the industry’s need for intuitive, visual solutions, BeerMaker will help to empower operators to manage their preferred operating procedures and have freedom to use the package on computers, tablet or mobile devices. Teams can gain greater process certainty by testing on a real-time digital twin, a complete and operational representation of the control system and a powerful tool for companies deciding on a new strategy to easily simulate new recipes.

Additional digital solutions based on ABB Ability™ Manufacturing Operations Management (MOM) have the capabilities to identify energy consumption, beer or extract losses and provide reporting functions and dashboard visualization. These include the ABB Ability™ BatchInsight concept, which can use big data analytics to identify process anomalies at the earliest stages. Operators and customer brewmasters will benefit from making decisions in real time to further improves processes, quality and productivity.

“We’re confident this is a technological package that is ready for advanced and digital solutions,” said Gernut van Laak, Brewmaster and Global Food and Beverage Solution Manager, ABB. “It can be applied within a customer’s installed base to enhance efficiencies and help reach sustainability targets.”

“We are using the full breadth of our automation and control system platform and connect the whole factory, including shop floor operations, simulation, digital and control room solutions, with less engineering and always with the possibility for expansion. We’re looking forward to further work with brewing customers to optimize to their plant specifics.”

Breweries will experience intuitive controls and high-performance human-machine interfacing, fast detection and resolution of process disturbances, consistent alarm messages, report management and standard operating procedures (SOPs), while engineers will benefit from a structured application design with process technology functions, and powerful pre-testing with built-in simulation.

@ABBgroupnews @abb_automation @drinktec #PAuto

#empowerthefield – release the potential!

97% of all instrument data at the field level is unused.

The new iTHERM TrustSens from Endress+Hauser, makes it possible to carry out continuous, traceable monitoring during the process thanks to a completely automated inline self-calibration function. This unique sensor technology represents a milestone in temperature measurement technology and offers added value, especially for users who need continuous monitoring of heating or sterilization processes. Apart from a high degree of process safety and improved system availability, iTHERM TrustSens furthermore eliminates the risk of nonconformities occurring during production.

97 percent of all instrument data at the field level is unused. With a live demonstration at its exhibit booth at BrauBeviale 2019 (Nuremberg {D}12-14/11/2019)*, the company will illustrate how customers can release this hidden potential. To support plant operators with the digitalization of their system components, they have developed their own IIoT ecosystem that focuses on the utilization and management of assets. In combination with the innovative diagnostics information from their Heartbeat technology, for instance, this makes it possible to determine the actual maintenance requirement or prevent unplanned system downtime.


When it comes to ensuring a consistently high level of quality during product manufacturing, inline measurement technology plays a decisive role. Whether it involves determining the pasteurization units in the heater, measuring the color in liquids or determining concentration-specific parameters via density, measurement values must be precise, reproducible and permanently stable. This is the only way to guarantee the required quality.

* Endress+Hauser will be presenting automation concepts and intelligent, self-monitoring measurement technologies that help make production processes safer and more efficient. Visitors will have the opportunity to learn how they can carry out precise measurements or satisfy process and system requirements in the age of Industry 4.0 with the help of intelligent instruments, complete solutions and services. Endress+Hauser will also present innovative calibration services and demonstrate how field instruments can be utilized to enable applications such as predictive maintenance or efficient asset management.
The Picomag electromagnetic flowmeter will also be on display, which offers compact flow measurements with integrated conductivity measurements in a handheld format, is suitable for use with water circulation systems, among other applications. (See also Magmeter upgraded.)
An additional product highlight for 2019 is the Promass Q Coriolis-based mass flow measurement instrument for demanding applications. This instrument relies on multi-frequency technology that makes it possible to precisely determine the degree of foam in ice cream or cream cheese, for instance. 
Another product tailored to the needs of the food industry is the cost-efficient Nivector FT126 capacitive level switch for all powders and fine-grained solids. This instrument offers best-in-class build-up monitoring performance. Thanks to IO-Link communications capability, the FT126 is also Industry 4.0-ready.

#Brewing #PAuto @Endress_Hauser @Endress_US @Endress_UK

Brewing at college!

Emerson is to collaborate with Colorado State University (CSU), in the United States, to build the Emerson Brewing Innovation Centre, where students will get hands-on experience using the latest automation technologies. Funded by a joint investment, the centre will serve as the main educational hub for the Fermentation Sciences and Technology programme and will reinforce advanced competencies for digital transformation as the Industrial Internet of Things (IIoT) era continues to evolve the industry.

With the number of US breweries increasing at a rate of 321 percent from 2007 to 2017, there is growing demand for highly skilled workers with expertise in fermentation sciences and proficiency in automation technologies. Emerson’s advanced automation solutions enable brewing companies to optimise operations, detect and address quality issues in real time, reduce downtime and shorten changeovers that occur when one beverage is changed out for another in production.

The CSU Department of Food Science and Human Nutrition attracts diverse, top-notch students to address the industry’s growing technology demand.

“Partnerships like these enable us to give our students experience with industry standards and help them prepare for the job market,” said Jeff Callaway, associate director of Fermentation Science and Technology at CSU. “The new centre will enhance our fermentation science academic programme while strengthening ties to the industry.”

The Emerson Brewing Innovation Centre will open this autumn in the Gifford Building on CSU’s main Fort Collins campus and feature two brewing systems that will allow students to gain experience using the latest real-world technologies driving innovation in the industry. Emerson Impact Partner Lakeside will build the systems that feature elements of Emerson’s Plantweb™ portfolio of IIoT technologies used in brewing automation: a DeltaV™ distributed control system, Micro Motion™ flow meters, Rosemount™ measurement technology and ASCO™ and Baumann™ valves.

Emerson’s collaboration with CSU is one of more than 350 secondary education partnerships worldwide that support finding solutions to address the skills gap in digital automation technologies.

“We are focused on helping train the digital workforce of the future while advancing education, innovation and diversity in the industry,” said Lal Karsanbhai, executive president of Emerson’s Automation Solutions business. “The Emerson Brewing Innovation Centre will mark the beginning of a strong and continued partnership with CSU.”

Emerson is donating $10,000 towards a CSU diversity fellowship to help set up the Brewing Innovation Centre and a scholarship for the fermentation programme.

@EMR_Automation #PAuto @ColoradoStateU #USA @HHC_Lewis 

Good healthy brewing in New Zealand.

Many do not fully appreciate that CO2 is toxic. This is possibly because it occurs naturally in the atmosphere, albeit at very low concentrations – around 400 parts per million (ppm). It is used or produced in the brewing and pub industry both during production and in the bar or restaurant, and we even produce it when we breathe out. We breathe CO2 out because it is toxic, of course, and great care is needed when working in environments where it may be present at elevated levels.

“Products which are specifically designed to detect hazardous gases are widely used within the oil and gas, marine and steel industries, and a similar picture is developing in the brewery industry,” says Crowcon’s Melina Ho. “So, when Manukau-based DB Breweries approached us to provide a gas detection solution, we were delighted to support.”

Melina explains: “Brewery industry employees who enter drinks storage areas without adequate gas monitoring equipment are potentially entering a life-threatening environment,”

Crowcon was initially asked to provide a quotation by the company’s health and safety advisors, a trend which is increasing within the food & beverage industry as the industry is currently upgrading its gas detection policies. This, along with the New Zealand Government’s initiative to reduce workplace accidents in the manufacturing sector, is driving demand for a gas detection solution with food and beverage as it proactively addresses the potentially catastrophic outcomes of workers becoming exposed to dangerous levels of CO2 gases.

If workers are equipped with personal monitors before they enter a risk zone, gas levels can be monitored. In DB Breweries case, Crowcon’s single-gas Gasman CO2 IR was selected largely due to its infrared sensors. Infrared sensors tend to have a faster response time and longer active life than other CO2 sensor technologies, as well as performing better at the lower temperatures that can be encountered in cellars. As part of the gas detection solution, service and calibration of instruments is provided.

CO2 is heavier than air. It is a hazard throughout the manufacturing process, right through to packaging and bottling, and even to the bars and eating establishments where the drinks are served. If CO2 escapes, it will tend to sink to the floor, where it can form deadly, invisible pockets. It collects in cellars and at the bottom of containers and confined spaces, such as tanks and silos.

DB Breweries spokesperson, Hamish Clentworth, explains: “One of the key factors in selecting Crowcon was the flexibility of its device. The ability to select the alarm function to best suit the working conditions whilst ensuring safety, is paramount, as it ensured minimal disruption when our sales teams visited bars, restaurants or retail outlets. Furthermore, the response time when increased CO2 levels are present was impressive, which meant our employees are alerted of the possibility high levels of CO2 in good time.

“Crowcon is one of the most popular choices across New Zealand and Australia, specifically within our industry and this proven track record was a deciding factor in our selection. Ultimately, our company has a duty to protect our employees from exposure to hazardous CO2 gases. Early detection can be the difference between life and death.”

Even when gas detectors are deployed; maintaining protection for every employee can be a challenge as CO2 can be present in several areas; gas detection devices must be an integral part of an employee’s daily routine.

Crowcon concludes, “We understand DB Breweries has made it company policy that employees use personal CO2 detectors at all times and we are hopeful this vital safety practice will be adopted more widely across the entire brewing and wine industry in the future.”

@Crowcon #PAuto #FoodDrink