Diversity – A natural advantage also
in process control engineering.
GEA Process Automation Solutions:
engineering for a better world GEA Process Engineering
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GEA Brewery Systems is a system integrator with
extensive process technology expertise. We deliver fully
automatic solutions for the entire range of automation and
information technology in addition to turnkey solutions.
We offer proven field-tested solutions that are individually
tailored to your processes. Our process control experts
select the right tools from the software available on the
market and adapt them to your needs. The combination
of our experience in process engineering and brewing
technology, and our extensive knowledge of the industry-
specific requirements is the key to making the right
decisions.
Diversity – a natural advantage also in process
control engineering
With our focus on system integration, we combine our
knowledge of process and plant engineering with software
products from the market leaders (e. g. Siemens WinCC &
BRAUMAT, Wonderware InTouch, GE Intelligent Platforms
iFIX, ProLeiT brewmaxx).
If necessary, by making appropriate adjustments, we are
flexible enough to be able to implement other solutions
perfectly adapted to local conditions.
Process control technology from the process
engineering specialists
More than 500 automation specialists are working in the
GEA Process Engineering segment. This network of experts
ensures that we provide the market with proven and sound
automation solutions.
The cutting-edge control tools we have developed
demonstrate our detailed process knowledge and enable
us to guarantee stable process conditions with maximum
efficiency and minimum energy consumption.
Automation and process control systems for breweries.
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GEARBOXX™
The GEARBOXX™ automation system is our solution
for the automation of our CRAFT-STAR™ and
COMPACT-STAR™ product range as well as our process
and utility units.
Depending on the HMI/SCADA system used, touch panel
or single-user systems as well as redundant multi-user
systems can be supplied. The streamlined and powerful
software based on SIMATIC S7 is the result of many years'
experience and consistent development.
Features: J Program structure according to S88 J Control of continuous and batch processes J Short cycle times thanks to the "time-slice" technique J Simulation of all peripheral modules J GEA equipment modules (MLM, IWM, etc.) J Innovative object classes (addressless programming) J Instance concept (freely selectable and changeable
peripheral addresses) J Optimized PID control algorithm J Support of PROFINET, PROFIBUS DP/PA and ASi
Based on the parameter settings, the optional Excel-
Engineering-Tool automatically generates the necessary
function and data blocks, ensures the consistent use of
symbols and comments, enables the upload of parameters
to the Exceltool and automatically creates the "as-built"
documentation.
MES
PCS
GEARBOXX™
GEARBOXX™Process control system
GEARBOXX™ MLM
GEARBOXX™ IWM
GEARBOXX™ Reporting (web-based) GEARBOXX™ Trending
based on SQL data baseMES functions
based on PC platform with Iltis or Panel IPC
GEARBOXX™ DialogGEARBOXX™ SequenceGEARBOXX™ Recipe ManagerGEARBOXX™ EventGEARBOXX™ Language
GEARBOXX™ XLSGEARBOXX™ S7
Add-on
Add-on
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OTAS™ –
comprehensive know-how
Since 1987, OTAS™ (Open Technology Automation
Solution) has been a constant in the computer-based
automation of breweries. Almost 30 years of experience
not only characterise OTAS™ but of course the detailed
know-how of our engineers. Today, plants with OTAS™
can be easily automated using either the unit-based S88
standard or the traditional process-oriented model.
Regardless of the SCADA platform used, OTAS™ provides
perfect control of brewery plants and processes. We offer
automation solutions that are tailored to your processes and
systems. Experience in automation technology and process
engineering as well as detailed knowledge of the brewing
industry are prerequisites for ultimately making the right
decision.
Our automation specialists select the right modules and
tools from the available standard hardware components
and software platforms, and adapt them to exactly suit your
needs.
In addition to the standard plant control and data
acquisition features, the range of functions also includes
production reports and recipes, batch tracking, support for
preventive maintenance, energy management and fault
analysis.
Based on PLCs and visualization software from renowned
manufacturers (Siemens, Rockwell, General Electric,
Invensys), OTAS™ consists of several modules that
have been developed in accordance with the specific
requirements of brewery automation and optimized
together with our customers.
User-friendly control systems.M
ESPC
SER
P
OTAS™
OTAS™Process control system
OTAS™ Report (web-based) OTAS™ Monitor
based on SQL data baseMES functions
based on WinCC, InTouch, iFIX or Iltis
OTAS™ DialogOTAS™ SequenceOTAS™ CombineOTAS™ EventOTAS™ LanguageOTAS™ Config
OTAS™ S7
OTAS™Interface manager (ERP/LIMS)
OTAS™ ServiceAdd-on
OTAS™ EnergyAdd-on
OTAS™ MLMAdd-on
OTAS™ IWMAdd-on
OTAS™ FermosAdd-on
OTAS™ DFMAdd-on
OTAS™ BrandAdd-on
RDBMSSQL
MS/Unify
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OTAS™ includes: J OTAS™ Dialog – consistent, clear and reliable plant
operation and visualization. J OTAS™ Sequence & Combine – recipe-based sequence
control including operator dialogs for manual
intervention. J OTAS™ Event – log of all automatic activities and
manual interventions. J OTAS™ Language – online language switching. Thanks
to Unicode, Cyrillic or Asian characters are not a
problem.
J OTAS™ Report – sequence and tank protocols presented
in Excel provide transparency from raw material intake
to packaging. The brew report contains all information
on each brew, including manually entered values and
texts. Even long-term analyses are possible based on the
brew journal and regular summary reports. J OTAS™ Monitor – current curves, reference curves and
individually configurable views enable an evaluation of
the process.
Optional modules: J OTAS™ Service – preventive maintenance, maintenance
logs and spare part ordering. J OTAS™ Energy – acquisition, processing and presentation
of process energy data, such as electric current and power,
steam and water volumes, etc. Based on these data, a
higher-level management system can increase efficiency. In
combination with OTAS™ Fermos, the peak refrigeration
demand can be effectively limited. J OTAS™ Remote – secure encrypted connection to our
service team at any time via the internet.
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Other modules in brief:
MLM – IWM – Fermos – DFM – Brand
Advanced modules for high quality standards
GEA Brewery Systems strives to meet the customer's
requirements. Reliability, efficiency, effectiveness and
always being one step ahead – these are our guiding
principles. Among other things, the modules MLM, IWM,
Fermos, DFM and Brand were developed to meet these
requirements.
Process values are continuously measured and
mathematically processed to enable a proactive automatic
response. Thus, a consistent high product quality is
guaranteed. These modules can be integrated in a variety
of system platforms. The operator is provided with a clear
user interface for operation and monitoring purposes. Ease
of use is one of our primary focuses.
The MLM (Multifunctional Lautering Management)
ensures high wort quality at constant lautering times and
high yields. Variations in the raw material quality are
automatically detected and compensated without manual
intervention. New products can be easily adjusted with a
few parameters.
Monitored brewing through automation.
The IWM (Intelligent Wort Management) ensures
constant evaporation rates through controlled energy
input. Differences in the wort volume, fluctuating vapour
pressures and boiler fouling are compensated by the IWM.
Fermos records the fermentation process and determines
the tank behavior over several batches. Based on the
resulting tank profile, Fermos takes over control and
improves the fermentation process. Complex laboratory
testing can thereby be reduced.
The DFM (Dynamic Filtration Management) is a process
control tool developed to optimize filtration run-time by
adjusting kieselguhr dosing rates. The aim is to obtain the
maximum filtration pressure at the end of the filter cycle
with the kieselguhr volume being utilized to the fullest
possible extent. At the same time, the type of kieselguhr
to be used is determined based on the turbidity values.
During filtration, the expected batch size is continuously
calculated to ensure the dosing vessels are empty at the end
of the filtration process. All values measured and calculated
during the ongoing filtration process are used for process
control.
Brand is an online monitoring tool comparing the so-called
"footprint" of different products against stored product
profiles. It automatically detects and reacts to deviations
thereby reducing losses.
PCS
MES
brewmaxx Visu-RecorderAdd-on
BRAUMAT
BRAUMAT Reporting with MS SQL Reportwriter
based on MS SQL data baseMES functions
BRAUMATProcess control system
BRAUMAT Logging and archivingBRAUMAT Trending
BRAUMAT Graphical recipe systemBRAUMAT Maintenance functionsBRAUMAT Diagnostics functionsBRAUMAT Language
BRAUMATInterface to SIMATIC IT
BRAUMAT Order systemAdd-on
BRAUMAT Route ControlAdd-on
FACTS & FIGURES:
J Many years of experience in the brewing industry characterize our automation solutions and the know-how of our engineers
J As integration specialists, we combine our knowledge of process and plant engineering with the hardware and software products of the market leaders
J We offer software modules that have been developed in accordance with the specific requirements of brewery automation and optimized together with our customers
J More than 500 automation specialists are working in the GEA Process Engineering segment.
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BRAUMAT –
the process control system for the entire beverage
production process
Flexible job and batch planning forms the basis for the
optimization of production processes. To achieve this goal,
effective monitoring, regulation and control are of utmost
importance. With BRAUMAT, the process control system
for the beverage industry, companies, plant managers and
operators can quickly and efficiently adjust production to
meet changing requirements at any time.
With a graphic recipe system, technologists can easily create
new recipes and adjust the production process as well as all
relevant parameters, such as quantities, temperatures and
occupation times, with just a few mouse clicks. Expertise
makes the difference!
Full transparency and an overview of all process data – in real
time and across the plant – can be obtained by connecting
BRAUMAT to SIMATIC IT, the Siemens MES system. In
this way, product quality and production efficiency can be
improved and energy consumption reduced.
brewmaxx™ –
the industry solution for breweries
The ProLeiT process control system brewmaxx™ has been
developed specifically for the requirements of breweries,
thus controlling, monitoring and optimizing the entire
process chain − from raw material intake to end product
filling, from production to enterprise system access.
Process-oriented materials management with batch
tracking and order-based route control, as well as
integrated MES functionality (brew reports, loss analysis,
workflow management, KPIs, OEE, energy data, etc.) with
standardized interfaces to ERP, LIMS and maintenance
systems, enables the analysis of all product relevant data in
real time. Furthermore, brewery-specific functions, such as
the equipment modules developed in close cooperation with
GEA Brewery Systems or the brewmaxx™ Visu-Recorder,
ensure the most efficient management of processes.
Besides controlling almost a fifth of the world’s overall beer
production, brewmaxx™ is available in seven language
versions and ideal for PLCs from Siemens and Rockwell
Automation.
ERP
MES
PCS
brewmaxx™ connectInterface manager
brewmaxx™ IntegrateMES functions
brewmaxx™ materialProcess-oriented materials management
brewmaxx™Process control system with recipe management
brewmaxx™ MessengerAdd-on
brewmaxx™ Equipment ModulesAdd-on
brewmaxx™ Routing ManagementAdd-on
brewmaxx™ Visu-RecorderAdd-on
PCS
MES
brewmaxx Visu-RecorderAdd-on
BRAUMAT
BRAUMAT Reporting with MS SQL Reportwriter
based on MS SQL data baseMES functions
BRAUMATProcess control system
BRAUMAT Logging and archivingBRAUMAT Trending
BRAUMAT Graphical recipe systemBRAUMAT Maintenance functionsBRAUMAT Diagnostics functionsBRAUMAT Language
BRAUMATInterface to SIMATIC IT
BRAUMAT Order systemAdd-on
BRAUMAT Route ControlAdd-on
GEA
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GEA Process Engineering
GEA Brewery Systems GmbHHuppmann Tuchenhagen
Locations:
Heinrich-Huppmann-Str. 1, 97318 Kitzingen, GermanyPhone +49 9321 303-0, Fax +49 9321 303-603
Am Industriepark 2–10, 21514 Büchen, GermanyPhone +49 4155 49-0, Fax +49 4155 49-2770
gea-brewerysystems @ gea.com, www.gea.com
We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity
GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX® Europe 600 index.