“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.

©2011InvensysSystems,Inc.Allrightsreserved.Nopartofthematerialprotectedbythiscopyrightmaybereproducedorutilizedinanyformorbyanymeans,electronicormechanical,includingphotocopying,recording,broadcasting,orbyanyinformationstorageandretrievalsystem,withoutpermissioninwritingfromInvensysSystems,Inc.

Invensys Operations Management • 5601 Granite Parkway III, #1000, Plano, TX 75024 • Tel: (469) 365-6400 • Fax: (469) 365-6401 • iom.invensys.com

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