Case Studies

Overview
A brewery required improvements to its existing Clean-in-Place (CIP) system to enhance cleaning consistency, reduce cycle times, and improve overall process reliability.

Challenge
The CIP system had inconsistent cleaning performance, inefficient cycle sequencing, and limited operator visibility. Variations in timing and control logic were affecting production efficiency and hygiene consistency.

Work
We reviewed and modified the PLC control logic to optimise CIP sequencing and timing. SCADA screens were updated to improve operator control and visibility. System parameters were refined to ensure consistent flow, temperature, and chemical dosing across all cleaning cycles.

Result
The updated system delivered more consistent cleaning performance, reduced CIP cycle times, and improved operational reliability. Operators gained better control and visibility, leading to smoother production and fewer process interruptions.

Overview
A brewery required improved control and monitoring of its fermentation tanks to ensure more stable fermentation conditions and better visibility for operators.

Challenge
The existing system had limited monitoring accuracy and inconsistent control of fermentation parameters such as temperature and pressure. Operators also lacked clear real-time visibility, making process adjustments less efficient.

Work
We updated the PLC control logic to improve fermentation stability and responsiveness. SCADA screens were redesigned to provide clearer real-time data and easier control access. Instrumentation inputs were refined to ensure accurate and reliable readings from all tanks.

Result
The upgrade delivered more stable fermentation conditions, improved process accuracy, and enhanced operator visibility. This resulted in better product consistency and more efficient day-to-day control of fermentation processes.

Overview
A brewery needed seamless integration of a new wort cooling system into its existing PLC and SCADA infrastructure to improve cooling efficiency and fermentation consistency.

Challenge
The existing control system was not configured to handle the new cooling equipment, leading to coordination issues between temperature control, flow management, and process timing. This created inconsistencies in wort temperature before fermentation.

Work
We modified the PLC logic to integrate the wort cooling system into the existing process sequence. SCADA screens were updated for real-time monitoring and operator control. Instrumentation and communication signals were configured to ensure accurate temperature feedback and coordinated system response.

Result
The integration delivered precise wort temperature control, improved cooling efficiency, and smoother process transitions into fermentation. Operators gained full visibility and control, resulting in more consistent brewing outcomes.