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Beer is not only a popular drink but aversatile and strongly market-depending product. The goal ofbreweries is to follow the marketdemands by continuous and costefficient development work and tosatisfy the customers by frequentlyproviding new sorts of high qualitybeers. A miniaturized brewery withhigh performance measuring andautomation technology offers bestsupport for that.

Siemens Prozess Instrumentationand Analytics is a leading supplierof process devices, analyzers andsystems and disposes of a very wideexperience in supplying brewerieswith measuring and automationtechnology. The successful instru-mentation of a new built miniatur-ized pilot brewing plant verifies thestrong position in this market.

Beer isnt just beer,but beer is a product that is offeredin a great variety after passingthrough a complex developmentprocess with extensive tests until itis ready for the market. Breweriesmust meet manifold marketdemands regarding, shelf life, alco-

hol content, flavor, color, durabilityetc. of the beer by providing a vari-ety of sorts which must be at any-time of constant taste and quality.Facing the typical boiling volume ofa brewery (some 250 hl up to 500 hlper batch) this causes remarkabledevelopments costs.

Beer isnt just beer, this is also sig-nificant for its manufacturing tech-nologies. Changes in raw materialquality and the high number ofbrewing processes, recipes andautomation technologies do contin-uously require further development

and optimization of the brewingplant units. This represents anothergreat cost.

The Ziemann Group, the worldslargest manufacturer and supplier ofbrewing plants, has identified thesescenarios and responded to them byengineering and building a pilotplant at their headquarters in Lud-wigsburg, Germany. The pilot plantis a unique miniaturized brewerywhich is totally equivalent to a realbrewery but much more flexible inits design and, with a boiling volumeof only 10 hl, a perfect and costeffective playground for beerdevelopers.

As part of a cooperation betweenthe Ziemann Group and SiemensAutomation and Drives (A&D), theentire automation and measuringtechnology of the pilot plant (con-trol system, drives and field devices)has been delivered and installed bySiemens.

True Industry Solution

Pilot Brewery totally relies onSiemens automation and fieldinstrumentation

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Ziemann Brewing Pilot PlantPlant Automation

The Ziemann pilot plantThe recently built Ziemann pilot plant isequiped with the same manufacturingtechnologies and plant units as realbreweries, but concentrated on an areaof only 100 m2.

For certain steps of the brewing processthe pilot plant provides alternative solu-tions (Fig. 1):

two malt processing alternatives:a traditional malt mill and the Zie-mann DISPAX unit,

two lautering systems: lauter tunsand mash filter, and

two wort boiling processes.

The vacuum evaporation unit elimi-nates unwanted flavor substances andthe whirepool is used for trub removal.After cooling of the wort in the cooler,cultured yeast is added and the fermen-tation occurs in the fernentation tank.

A number of by-plants (utilities) areused for cleaning (CIP) and cooling andto supply steam and compressed air.

Tasks and uses

Ziemann is a process OEM and suppliescomplete plants. Therefore, the pilotplant is mainly used to develop owntechnologies and to test new processesregarding their readyness for market-ing. Another objective of the plant is totrain own and customer personnelunder real conditions that leads to

shorter and trouble-free plant installa-tion and commissioning.

The pilot plant is also used to test newmeasuring principles and devices.

Automation from one hand

The whole process automation eqip-ment including field devices and analyz-ers has been planned, delivered,installed and commissioned turnkey bySiemens as part of the partnership con-tract between Ziemann and SiemensAutomation & Drives. Installation com-

prises the control system BraumatPCS 7, various field devices, motors andfrequency converters, remote I/Os andthe low-voltage systems.

Industry solution Braumat PCS 7

Automation of the pilot plant is accom-plished using the Braumat PCS7 controlsystem (Fig. 2) to control the entire pro-duction process.

Braumat PCS 7 realizes the concept of aspecialized, recipe-based automationsystem for the brewing industry. It usesspecial libraries and program modulesand forms a true industry solution. The

modular design allows for fragmenta-tion of the process steps in smaller unitsas requested by the ISA-S88 standard.

A user statement confirms this impor-tant feature and the experiences withthe Braumat PCS 7:

Fig. 2: Conducting observation point with

PCS 7

With the pre-designed modules of the

Braumat Library we can very well influ-ence and control the process, inplementour applications and adapt the processto the changing quality of the raw mate-rials.

This fexibility is of great and cost reduc-ing importance during developping andtesting of new sorts of beer.

Malt feed

Whirlpool

Malt mill

Wort boiler 1

Mash filter

Lauter tunMash vessel

Wort cooling

Yeast tanksCIP

Mash pan

Wort boiler 2

DISPAX

Tank plant

Vacuum-

evaporation

-

Fig. 1: Construction of the Ziemann-pilot plant Fig. 3: Ziemann technology room, plant

detail

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Field Instrumentation

Sanitary demands on levelmeasurementIndustrial hygiene is a key issue in thefood and beverage industry. Measuringdevices used in this industry segmentmust meet high sanitary demands andbe capable for use with SIP (SterilisationinPlace) and CIP (Cleaning in Place) pro-cedures.

Therefore, Ziemann decided to use thenew Siemens SITRANS P300 pressuretransmitter in its pilot plant for liquid

level determination. The P300 meetseasily all application specifications:

On open brewing vessels the P300pressure transmitter measures thehydrostatic pressure of the liquid col-umn at the bottom of the vessel andfrom there determines the liquid level

In the closed vessels of the fermenta-tion and storage tanks the liquid levelis monitored using two P300 pressuretransmitters. The reason for that isthe overpressure that exists abovethe liquid level in the tanks.One pressure transmitter, installed atthe bottom of the vessel, measuresthe hydrostatic pressure plus thesuperposed overpressure, while thesecond transmitter determines thepressure above the liquid level. Fromboth measured values the liquid levelis calculated by the process control-ler.

Solution with Siemensprocess devicesThe process devices installed in the pilotplant (Table 1 ) comprise pressure trans-mitters for use in the food and beverageindustry, flow and level measuringdevices, conductivity measuring cellsand microwave level limit switches.

Some devices at a glance:

SITRANS P300Pressure transmitter in stainless steelhousing and with flush mounted dia-

phragm for use at the fermentation andstorage tanks.

POINTEK CLS 100Inverse frequency-based capacitive2-wire level switch for use in severaltanks.

MAGFLO MAGElectromagnetic-inductive volumeflowmeter MAGFLO MAG 1100 F withMAG 6000 transmitters

SITRANS TTemperature transmitter used in thecellar area

SIWAREXWeighing system comprising sensors,devices and weighing modules

SIPAN 322-wire inductive conductivity measure-ment for SIP/CIP applications

SITRANS P300

The SITRANS P300 pressure transmitterhas been especially designed for use inthe food & beverage industry. Thehousing is made from stainless steeland comprises also the data processingelectronics. The front-flush measuringcell provides best conditions for deadspace free measurements and allowssimple cleaning on site. With its mea-suring range up to 150 C the P300 issuited to Sterilisation in Place withoutshowing any drift effects. The measur-

ing deviation of 0.075 % max. and long-term drift of only 0.25 % over 5 years setnew benchmarks in the food industry.The very small measuring deviation per-mits to operate the process closer to theoptimum degree of efficiency and thusto increase plant productivity.

In case of process temperatures riseabove 150 C a temperature decouplertakes care for a continuous high mea-suring precision. This unit, in contrastto other pressure transmitters, does notdecrease the measuring precision and,additionally, is more cost effective.

The design of the P300 complies withthe regulations as specified by theEHEDG (European Hygienic Engineering& Design Group) and with the standardsof the 3-A Sanitary Standards, Inc.

SITRANS P300 29

POINTEK CLS 100 32

SITRANS T 37

SITRANS FM 11

SIPAN 32 1

SIWAREX 1Table 1: Quantity of field devices

Fig. 4: SITRANS CLS Level transmitter Fig. 5: SITRANS P300 Pressure transmitter

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Siemens AG

Automation and DrivesSensors and CommunicationProcess Analytics76181 KARLSRUHEGERMANY

www.siemens.com/processanalytics Siemens AG 2007Subject to change without prior notice

Case Study

User benefits ...Versatile user benefits arise from thisproject:

The close combination of brewingtechnology, brewing plant enginer-ing and automation technology,

the close combination of measur-ing and automation technologyand the resulting all from onehand concept,

the wide range of dedicated ser-vices provided from the BraumatPCS 7 control system for the brew-ing industry and

the technical features of theinstalled process devices.

High product quality combined withcost effective plant operation resultfrom that and create remarkableadvantages in competition. Someexamples are given in the following.

... from the combination ofmeasuring and automation

Ziemann is user of automation tech-nology in the pilot plant and supplieras part of a turnkey plant delivery. Inthis dual positions the all from one

hand concept has a particular impor-tant meaning: Regarding the ownpilot plant and the delivered plantZiemann can be sure, that e. g.

Automation system and measuringdevices fit to each other,

the system-internal communica-tions are seamless and use useidentical interfaces (PROFIBUS PA),and

the operators need only one tool tohandle the whole system.

That all saves costs along the life-cycle of the plant, starting with instal-

lation and training, followed by sta-ble operation with high availabilityand reduced maintenance efforts.

... from the combination of

brewing and automation

The combination of Ziemann planttechnology with the package ofautomation and measuring technol-ogy from Siemens offers breweriesremarkable added value with regardto technical advance and reduces life-cycle costs.

... from the PCS 7 control system

Braumat PCS 7 is of fine-modulardesign and allows to divide the pro-cess steps into minor units.

The pre-designed modules of the

Braumat Library help to implementspecial applications in short time.

Plant structure and brewing pro-cess are mapped according toISA S88 Standard which means anefficient support of plant planningand operation.

Braumat PCS 7 is based on theseamless automation technologyof Siemens Totally Integrated Auto-mation (TIA), from malt feed tofinal filling.

Braumat PCS 7 is scalable and suit-able for use in small as well as large

breweries.

... from the process devices

SITRANS P300Reliable and very accurate measur-ing results through measuringdeviation of 0.075 % max., sanitarystainless steel housing, front-flushmeasuring cell and extensive diag-nostic.

POINTEK CLS 100Reliable level monitoring evenunder harsh conditions throughInverse Frequency Shift technol-ogy.

SITRANS FMReliable flow measurementthrough magnetic-inductive mea-suring and use of specialized ver-sions for specific applications.