Optimizing Brew House Efficiency With Advanced Automation
Overview
A leading brewing enterprise aimed to reduce its brew house cycle time from 3 hours to 2.5 hours to improve efficiency and throughput across key processes. The client partnered with ACL Digital to implement an advanced automation solution covering system design, development, testing, and commissioning to enable streamlined operations.
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Challenges
Extended Cycle Times
Manual interventions and lack of process synchronization increased the overall brew house cycle duration
Limited Process Visibility
Lack of centralized monitoring restricted real-time insights and delayed decision-making
Inconsistent Process Control
Variability in parameters across brewing stages led to inconsistent output quality and inefficiencies
Fragmented Automation Architecture
Disconnected systems across milling, mashing, fermentation, and downstream processes created coordination gaps
Inefficient Testing and Commissioning
Lack of simulation capabilities increased deployment risks and extended commissioning timelines
Solution
ACL Digital delivered the project through structured phases, ensuring a systematic and risk-controlled implementation
- ControlLogix PLC-Based Control System Implementation: Enabled precise process control and improved coordination across the brew house
- iFIX SCADA Implementation: Provided centralized monitoring, real-time visualization, alarm management, and operator control
- Integrated Process Automation: Unified control across all stages including milling, mashing, fermentation, filtration, and packaging
- Simulation-Driven Validation: Enabled simulation to validate logic and reduce risks before deployment
- Pre-Commissioning and Commissioning: Executed dry and wet commissioning phases to ensure system reliability and seamless go-live
Outcomes
- Reduced Brew House Cycle Time: Achieved cycle time reduction from 3 hours to 2.5 hours
- Improved Process Consistency: Standardized control ensured stable and repeatable operations
- Enhanced Operational Visibility: Enabled faster, data-driven decision-making through real-time monitoring
- Increased Throughput: Improved production capacity without additional infrastructure
- Reduced Commissioning Risks: Simulation-led validation minimized errors and accelerated deployment
