Siemens AG 2007

True Industry Solution Pilot Brewery totally relies on Siemens automation and field instrumentation

Beer isnt just beer,

but beer is a product that is offered in a great variety after passing through a complex development process with extensive tests until it is ready for the market. Breweries must meet manifold market demands regarding, shelf life, alcohol content, flavor, color, durability etc. of the beer by providing a variety of sorts which must be at anytime of constant taste and quality. Facing the typical boiling volume of a brewery (some 250 hl up to 500 hl per batch) this causes remarkable developments costs. Beer isnt just beer, this is also significant for its manufacturing technologies. Changes in raw material quality and the high number of brewing processes, recipes and automation technologies do continuously require further development and optimization of the brewing plant units. This represents another great cost. The Ziemann Group, the worlds largest manufacturer and supplier of brewing plants, has identified these scenarios and responded to them by engineering and building a pilot plant at their headquarters in Ludwigsburg, Germany. The pilot plant is a unique miniaturized brewery which is totally equivalent to a real brewery but much more flexible in its design and, with a boiling volume of only 10 hl, a perfect and cost effective playground for beer developers. As part of a cooperation between the Ziemann Group and Siemens Automation and Drives (A&D), the entire automation and measuring technology of the pilot plant (control system, drives and field devices) has been delivered and installed by Siemens.

Beer is not only a popular drink but a versatile and strongly marketdepending product. The goal of breweries is to follow the market demands by continuous and cost efficient development work and to satisfy the customers by frequently providing new sorts of high quality beers. A miniaturized brewery with high performance measuring and automation technology offers best support for that.

Siemens Prozess Instrumentation and Analytics is a leading supplier of process devices, analyzers and systems and disposes of a very wide experience in supplying breweries with measuring and automation technology. The successful instrumentation of a new built miniaturized pilot brewing plant verifies the strong position in this market.

Case Study March 2007

 Siemens AG 2007

Ziemann Brewing Pilot Plant Plant Automation

The Ziemann pilot plant

The recently built Ziemann pilot plant is equiped with the same manufacturing technologies and plant units as real breweries, but concentrated on an area of only 100 m2. For certain steps of the brewing process the pilot plant provides alternative solutions (Fig. 1): two malt processing alternatives: a traditional malt mill and the Ziemann DISPAX unit, two lautering systems: lauter tuns and mash filter, and two wort boiling processes. The vacuum evaporation unit eliminates unwanted flavor substances and the whirepool is used for trub removal. After cooling of the wort in the cooler, cultured yeast is added and the fermentation occurs in the fernentation tank. A number of by-plants (utilities) are used for cleaning (CIP) and cooling and to supply steam and compressed air. Tasks and uses Ziemann is a process OEM and supplies complete plants. Therefore, the pilot plant is mainly used to develop own technologies and to test new processes regarding their readyness for marketing. Another objective of the plant is to train own and customer personnel under real conditions that leads to

shorter and trouble-free plant installation and commissioning. The pilot plant is also used to test new measuring principles and devices. Automation from one hand The whole process automation eqipment including field devices and analyzers has been planned, delivered, installed and commissioned turnkey by Siemens as part of the partnership contract between Ziemann and Siemens Automation & Drives. Installation comprises the control system Braumat PCS 7, various field devices, motors and frequency converters, remote I/Os and the low-voltage systems. Industry solution Braumat PCS 7 Automation of the pilot plant is accomplished using the Braumat PCS7 control system (Fig. 2) to control the entire production process. Braumat PCS 7 realizes the concept of a specialized, recipe-based automation system for the brewing industry. It uses special libraries and program modules and forms a true industry solution. The modular design allows for fragmentation of the process steps in smaller units as requested by the ISA-S88 standard. A user statement confirms this important feature and the experiences with the Braumat PCS 7:

Fig. 2: Conducting observation point with PCS 7

With the pre-designed modules of the Braumat Library we can very well influence and control the process, inplement our applications and adapt the process to the changing quality of the raw materials. This fexibility is of great and cost reducing importance during developping and testing of new sorts of beer.

Malt feed

Malt mill

Mash vessel

Lauter tun

DISPAX

Mash pan

Mash filter

Tank plant

Wort cooling

Whirlpool

Wort boiler 1

CIP

Yeast tanks

Vacuumevaporation

Wort boiler 2

Fig. 1: Construction of the Ziemann-pilot plant

Fig. 3: Ziemann technology room, plant detail

 Siemens AG 2007

Field Instrumentation

Sanitary demands on level measurement

Industrial hygiene is a key issue in the food and beverage industry. Measuring devices used in this industry segment must meet high sanitary demands and be capable for use with SIP (Sterilisation inPlace) and CIP (Cleaning in Place) procedures. Therefore, Ziemann decided to use the new Siemens SITRANS P300 pressure transmitter in its pilot plant for liquid level determination. The P300 meets easily all application specifications: On open brewing vessels the P300 pressure transmitter measures the hydrostatic pressure of the liquid column at the bottom of the vessel and from there determines the liquid level In the closed vessels of the fermentation and storage tanks the liquid level is monitored using two P300 pressure transmitters. The reason for that is the overpressure that exists above the liquid level in the tanks. One pressure transmitter, installed at the bottom of the vessel, measures the hydrostatic pressure plus the superposed overpressure, while the second transmitter determines the pressure above the liquid level. From both measured values the liquid level is calculated by the process controller.

Solution with Siemens process devices

The process devices installed in the pilot plant (Table 1 ) comprise pressure transmitters for use in the food and beverage industry, flow and level measuring devices, conductivity measuring cells and microwave level limit switches. Some devices at a glance: SITRANS P300 Pressure transmitter in stainless steel housing and with flush mounted diaphragm for use at the fermentation and storage tanks. POINTEK CLS 100 Inverse frequency-based capacitive 2-wire level switch for use in several tanks. MAGFLO MAG Electromagnetic-inductive volume flowmeter MAGFLO MAG 1100 F with MAG 6000 transmitters SITRANS T Temperature transmitter used in the cellar area SIWAREX Weighing system comprising sensors, devices and weighing modules SIPAN 32 2-wire inductive conductivity measurement for SIP/CIP applications
SITRANS P300 POINTEK CLS 100 SITRANS T SITRANS FM SIPAN 32 SIWAREX Table 1: Quantity of field devices 29 32 37 11 1 1

SITRANS P300 The SITRANS P300 pressure transmitter has been especially designed for use in the food & beverage industry. The housing is made from stainless steel and comprises also the data processing electronics. The front-flush measuring cell provides best conditions for dead space free measurements and allows simple cleaning on site. With its measuring range up to 150 C the P300 is suited to Sterilisation in Place without showing any drift effects. The measuring deviation of 0.075 % max. and longterm drift of only 0.25 % over 5 years set new benchmarks in the food industry. The very small measuring deviation permits to operate the process closer to the optimum degree of efficiency and thus to increase plant productivity. In case of process temperatures rise above 150 C a temperature decoupler takes care for a continuous high measuring precision. This unit, in contrast to other pressure transmitters, does not decrease the measuring precision and, additionally, is more cost effective. The design of the P300 complies with the regulations as specified by the EHEDG (European Hygienic Engineering & Design Group) and with the standards of the 3-A Sanitary Standards, Inc.

Fig. 4: SITRANS CLS Level transmitter

Fig. 5: SITRANS P300 Pressure transmitter

 Siemens AG 2007

Case Study

User benefits ...

Versatile user benefits arise from this project: The close combination of brewing technology, brewing plant enginering and automation technology, the close combination of measuring and automation technology and the resulting all from one hand concept, the wide range of dedicated services provided from the Braumat PCS 7 control system for the brewing industry and the technical features of the installed process devices. High product quality combined with cost effective plant operation result from that and create remarkable advantages in competition. Some examples are given in the following. ... from the combination of measuring and automation Ziemann is user of automation technology in the pilot plant and supplier as part of a turnkey plant delivery. In this dual positions the all from one hand concept has a particular important meaning: Regarding the own pilot plant and the delivered plant Ziemann can be sure, that e. g. Automation system and measuring devices fit to each other, the system-internal communications are seamless and use use identical interfaces (PROFIBUS PA), and the operators need only one tool to handle the whole system. That all saves costs along the lifecycle of the plant, starting with installation and training, followed by stable operation with high availability and reduced maintenance efforts.

... from the combination of brewing and automation The combination of Ziemann plant technology with the package of automation and measuring technology from Siemens offers breweries remarkable added value with regard to technical advance and reduces lifecycle costs. ... from the PCS 7 control system

... from the process devices

SITRANS P300

Braumat PCS 7 is of fine-modular

design and allows to divide the process steps into minor units. The pre-designed modules of the Braumat Library help to implement special applications in short time. Plant structure and brewing process are mapped according to ISA S88 Standard which means an efficient support of plant planning and operation. Braumat PCS 7 is based on the seamless automation technology of Siemens Totally Integrated Automation (TIA), from malt feed to final filling. Braumat PCS 7 is scalable and suitable for use in small as well as large breweries.

Reliable and very accurate measuring results through measuring deviation of 0.075 % max., sanitary stainless steel housing, front-flush measuring cell and extensive diagnostic. POINTEK CLS 100 Reliable level monitoring even under harsh conditions through Inverse Frequency Shift technology. SITRANS FM Reliable flow measurement through magnetic-inductive measuring and use of specialized versions for specific applications.

Siemens AG
Automation and Drives Sensors and Communication Process Analytics 76181 KARLSRUHE GERMANY

www.siemens.com/processanalytics

Siemens AG 2007 Subject to change without prior notice