Post on 17-Feb-2022
“The comprehensive Invensys MES solution has provided a significant increase in the accuracy of our process control system enabling our operators to monitor the manufacturing lines in real time and more quickly react to anomalies that might occur.”
Yuriy ChentyrevDirector of Operations
Baltika Masters Brewing Automation with Invensys MES Software Solution
Goals• Thebreweryrequiredamodularautomation
softwaresolutionthatwouldenableoperationsmanagementtoscalethesystemtomeetfutureproductionrequirements
• Reducecoststhroughimprovedequipmentperformance,loweredmateriallosses,reducedproductioncostsandbettersupplychainprocessesfromdistributorwarehouses
Challenges• Ensuringthatanewautomationsoftware
solutioncouldeffectivelyintegratewithexistinghardwareandsoftwarewhileincreasingoverallequipmentperformance
• Becauseaccuratelymonitoringsuppliesofsourceingredientsiscriticaltomaintainingadequatelevelsofbrewingproduction,therewasconcernthatanappropriatesoftwaresolutionmaynotbeavailable
• Withincreasingglobalcompetition,reducingthefacility’sproductioncostwasatoppriorityforanynewsoftwareimplementation
Solutions and Products• WonderwareEquipmentOperationsModule• WonderwareInTouchHMI• WonderwareMES/Performance• WonderwareInformationServer• WonderwareSystemPlatform
Results• Thereductionof8percentinenergyusage
duringthemanufacturingprocesshasenabledBaltikatoloweritsoveralloperatingcosts
• A5percentreductioninsteamconsumptionduringthebeermanufacturingprocesshasbeenachieved
• Thecostofpackagingmaterialshasbeenloweredby1.8percentannually
• Baltikacannowaccuratelydetermineproductionlossesperbatchandhasachievedareductionof0.56percentinextractloss
INDUSTRY:FOOD&BEVERAGE
Baltika Brewerieswww.baltika.ru
St. Petersburg, Russia –Beerisoneoftheworld’soldestbeveragesdatingbacktothe6thmillenniumB.C.Todaythepopularityofthebeveragecontinueswithmorethan133billionliterssoldworldwideeachyear.Thesimpleprocessoffermentingamixtureofwater,barleyandhopshasbecomea$295billionindustry,andalmosteverycountryintheworldhasastakeinmakingbrew.
Withmorethan200yearsofbrewinghistory,beerproductioninRussiaisconsideredoneofthepotentiallyfastestgrowingcommercialindustriesinthecountry.TheCarlsbergGroupquicklyrecognizedthatbeerproductioninRussiawasapotentiallylucrativebusinessandinvestedinBaltikaBreweries,oneofthecountry’soldestbrewhouses.
Toremaincompetitiveandtokeepprofitsflowing,Baltikarevieweditsmanufacturingprocessesin2007anddecidedtoinvestinnewsolutionstohelpimproveitsautomatedproductionprocessesandincreasetheprofitabilityofitsoperations.Inconjunctionwithitsparentcompany,theCarlsbergGroup,Baltikaproductionmanagementdecidedtostandardizethecompany’scorporateandmanufacturingITsystemsonWonderwareMESsoftwarefromInvensysOperationsManagement.Thecompany’sdecisionwasnotonlybasedontheadvancedtechnologiesincorporatedintheWonderwareMESsolution,butalsothereputationandexperienceofInvensysandtheWonderwarebrandinsuccessfulimplementationsatotherbreweriesaroundtheglobe.
Beer Production “Hops” On Technology Bandwagon
BaltikaBreweriesisthelargestbeerproducerinRussiawitha41percentmarketshareandaproductioncapacityof50millionhectolitersperyear.ThecompanymaintainsbrewingsitesthroughoutRussiaaswellasinAzerbaidjan.Withitsextensiveproductportfolioof30beerand10non-beerbrandsandexportstomorethan60countriesworldwide,Baltikaneededatechnologysolutionthatwouldenableittobettermanagemanufacturingandmaintainaccurateproductionrecords.Management’soverallgoalwastoreduce
costsperunitthroughimprovedequipmentperformance,lessmaterialloss,bettersupplychainprocessesfromdistributorwarehousesandtightcontrolsonproductioncosts.
Baltikaoutlinedveryspecificsystemdesignparametersforthenewautomatedsoftwaresolutionincludingamodular,scalableplatformthatwouldenablethecompanytoexpanditsmanufacturingcapabilitiestokeeppacewithmarketdemand.Theautomationsolutionalsohadtoprovideanopenarchitecturethatcouldeasilyintegratewithcurrentandfuturethird-partysystems,loweroverallmaintenancecostsandkeepengineeringexpensestoaminimum.WorkingwithVentCompany,aWonderwarecertifiedsystemintegrator,theimplementationoftheWonderwareMESsolutionbeganin2007atBaltika’sSamarafacility.TheInvensyssolutionsinstalledincludedWonderwareInTouchHMIforprocessvisualization,WonderwareEquipmentOperationsModulefortrackingandtraceability,WonderwareInformationServerforcorporate-wideaccesstodata,andWonderwareMES/Performancesoftwaretocollect,trackandcommunicatereal-timeequipmentperformanceandefficiencyinformationandKPIs.ThefoundationofthesepowerfulInvensystechnologycomponentsisWonderwareSystemPlatform,whichprovidesBaltikawithasingle,scalableplatformforallSCADA,supervisoryHMIandMESapplicationsrequiredbythecompany.
“PriortoimplementingtheInvensysMESsolution,Baltikausedacustom-builtsystemfordatacollectionandanalysis,”saidYuriyChentyrev,DirectorofOperationsatBaltika.“AllprocessdatawasmanuallyenteredbyplantoperatorsintoMicrosoftExcelortheMonolitProductiondatabase,whichwasatime-consumingprocessandpronetoerrors.Thedatawasthenincorporatedintoaspreadsheettogenerateproductionanddataanalysisreportsformanagement,butthesewerenotalwaysaccurate.Baltikadesperatelyneededamoreprecisemethodtomanagedatadetailingplantoperationsandfinalbeerproductionstatistics.”
Invensys Software Elevates Brewery Precision
Toovercometheshortcomingsofthepriorcustomproductionmanagementsystem,Baltika’sobjectivefortheInvensyssolutionwastoloweroveralllaborcosts,improvetimingofinformationanalysisreports,facilitatefasterdecision-makingandimprovethecredibilityofdataacquireddetailingproductionprocessesandthefinalendproduct.
ThescopeoftheprojectbasedontheInvensyssolutionincludedsuccessfullyintegratingtheMESsystemwiththebrewery’sexistingProLeiTprocesscontrolsystemaswellaswithvariouscontrolsystemsthatmanageBaltika’sfillinglinemachinesfromdifferentequipmentsuppliers.Thefirststagetargetedseveraloperationalandperformancefunctionsincludingtheplant’ssupervisorycontrolsystemstoaddressdowntimecontrolandefficiencyanalysisforthefillingshop.
Thesolutionalsowastomanagegenealogyandtraceabilityfunctionsfortheproductionprocessandtheindustrialdatabaseforprocessdatastorage.Inaddition,aWebportalwouldbeestablishedforpublishingreportsthatcouldbeaccessedcompany-wide.
ThescopeoffacilitiesoperationstobemanagedbyWonderwaresoftwarewasquiteextensiveandincludedtheproductionlaboratory,elevatorandwarehousesaswellasmaltpreparation,boiling,brewingandfiltrationshops.Intotal,morethan200piecesofequipmentneededtoberunbytheInvensyssolution.
Toprovideextensivevisualizationoftheentirebrewingoperations,WonderwareInTouchwasthesoftwareofchoice.WonderwareInTouchprovidesBaltikaplantoperatorsreal-timeviewsoftheproductionprocessestoensurealllinesarefunctioningatoptimumlevels.TheWonderwareInTouchscreensateachoperatorstationprovidesophisticatedgraphicvisualizationdisplaysdetailingoperationalstatusthroughouttheentiremanufacturingprocess,frombrewingtopackaging.
WonderwareInTouchalsooffersfeaturesthatwerenotavailabletooperationsmanagementbythepriorsystemincludingresolution-independentgraphicsandintelligentsymbolsthatenabledirectinteractionwiththeprocessingsystem.Thetechnologyalsoincludessophisticatedscriptingtoextendandcustomizeapplicationsforthecompany’sspecificneeds,real-timedistributedalarmingwithhistoricalviewsforanalysis,andbuilt-in,real-timeandhistoricaltrendingforreportingandanalysisofoperationsefficiency.
NotonlyareplantmanagersattheSamarafacilitynowabletoaccesscriticalproductiondata,butsocanexecutivesatthecompany’sheadquartersinSt.Petersberg.UsingWonderwareInformationServer,decision-makersthroughoutthecompanycanquicklygainvisibilitytoproductionoperationsthroughWebreportspublishedintheWonderwareInformationServer.AsanintegratedWebserver,WonderwareInformationServersimplifiestheorganizationanddeliversoperationsinformationforuseacrossallfunctionsinBaltika’sorganization.
BaltikaalsoemploystheWonderwareEquipmentOperationsModuletocapturereal-timeprocessdataandprovidedetailedbatchdatareportsforanalysis.WiththeWonderwareEquipmentOperationsModule,Baltikacantrackeachrawmaterialthatisusedduringthebrewingprocess.
Thesoftwarealsocapturestraceabilityrecordswhichenablerapidresponsefromplantoperatorstoeventssuchproductrecalls.Inaddition,thesoftware’srecipemanagementsystemenablesthebrewertocontrolingredientsinamoreprecisewayandprovidesproductdevelopmentgenealogythatenablesthecompanytotrackproblemsbacktothesourceifnecessary.
PairedwiththeWonderwareSystemPlatform,acomprehensiveindustrialsoftwareplatformforSCADA,HMIandMESapplications,WonderwareEquipmentOperationsModuleprovidescomprehensivedatamanagementandseamlessinteractionwiththeWonderwareInTouchHMIandotherplantfloorvisualizationsystems.
“ThecomprehensiveInvensysMESsolutionhasprovidedasignificantincreaseintheaccuracyofBaltika’sprocesscontrolsystemenablingplantoperatorstomonitorthemanufacturinglinesinrealtimeandmorequicklyreacttoanomaliesthatmightoccur,”saidChentyrev.“TheimplementationoftheInvensyssolutionalsoprovidedBaltikawithahigherleveloftraceabilitybasedonaccuratereal-timedata.TheInvensysMESsystemhasnowbecomeaneffectivetooltopromptlyreacttothechangesinqualitativeindicatorsordisclosehiddendeficienciesthatcanleadtoproductionlossesorequipmentshutdowns.”
WiththeWonderwareMES/PerformancesoftwareBaltikaisabletobettermonitorplantperformanceandtheuseofrawmaterialsaswellasprovidedetaileddowntimeanalysesforgreaterassetutilization.BaltikaalsohasachievedsignificantincreasesinplantproductivityandefficiencythroughOEE(OverallEquipmentEffectiveness)monitoringandreporting.Theproductioneventscannowbeadjustedandcontrolledattheproductionlevelandthecompanyisabletobettercalculatemateriallossinrealtimebyproductlot.
“Baltikaalsohasgreatlyimproveditsapproachtoplannedmaintenanceactivities,”saidChentyrev.“PriortotheInvensysMESsoftwaresolution,managementkeptapapertrailofvariousfacilitydowntimeoccurrences.NowoperatorscanrelyonmoreaccurateParetochartsandmachinestatisticsdatawhichhavevastlyimprovedBaltika’smaintenancemanagementoperations.Inaddition,byrecordingallproductioneventsandmachinestats,Baltikaisabletoautomaticallydefinethecauseofunplannedlineshutdowns.”
Baltika Achieves a Blend of Benefits
TheInvensysprojecthasbroughtevenlargereconomicbenefitsinboththemanufactureofBaltika’svariousbeveragesaswellasstreamliningmanagementoffacilityoperationsofthebrewery.Someofthekeyoperationssavingsincludedanannualdecreaseof5percentinsteamproductioncostsduringthebeermakingprocess;areductionof0.56percentinextractloss;an8percentenhancementinenergyuse;anda1.8percentdecreaseinpackagingmaterialcosts.
BaltikaalsoplanstousetheInvensystechnologytooptimizeitssupplychainactivitiesbyextendingintegrationofthesoftwaretothecompany’sERPMonolitschedulingsystem.TheobjectiveistoenablemanagementandkeyplantoperatorstodownloadproductiondatafromtheERPsystemandcoordinateitwithschedulingandproductiontasksmanagedbytheInvensysMESsystem.TheMESsystemwillthenbeabletogeneratereportsthatwillassistinmoreefficientmanagementoftheoverallproductionprocessrangingfrommonitoringrawmaterialsuppliestomanagingthemanufacturingprocesstopackaginganddistribution.
Thoughearlybrewhouseswerefairlyprimitiveandusedavarietyofmethodsformakingbeer,thebeermanufacturingprocesshasnotchangedmuchsincetheIndustrialRevolutionintroducedmodernmethodsandtools.Today,governmentregulationsandincreasingpublicdemandhaveputmorepressureonbreweriestoimproveproductqualityandreducecoststoremainprofitable.TechnologyfromInvensysismakingiteasierforBaltikaandotherbreweriestomoreeffectivelytracktheproductionprocess,managerawmaterialprocessinganddelivertomarketahighqualityproduct.
Invensys,theInvensyslogo,ArchestrA,Avantis,Eurotherm,Foxboro,IMServ,InFusion,SimSci-Esscor,Skelta,Triconex,andWonderwarearetrademarksofInvensysplc,itssubsidiariesoraffiliates.Allotherbrandsandproductnamesmaybethetrademarksorservicemarksoftheirrepresentativeowners.
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