Carlsberg's Mysore factory, located in Nanjangud, has an annual production capacity of 0.8 million hectoliters and produces multiple SKUs to cater to diverse consumer preferences. As part of its ongoing commitment to ensuring accuracy, consistency and transparency, Carlsberg has digitized critical processes, specifically the recording of brewing and filtration data, which were previously managed manually.
Brewing Industry 4.0
Carlsberg's digital transformation with Siemens enhances brewing efficiency, quality and sustainability through real-time data integration and automation.
Carlsberg’s digitalization journey
Enhancing transparency and operational efficiency
Precision brewing: A vision for the future
Carlsberg wanted to eliminate manual data entry by automating data collection from PLC tags. By integrating data from SCADA systems directly to the Digitalization PC, Carlsberg ensured that data is mirrored in real-time.
Dashboards: The heartbeat of digital brewing
Carlsberg wanted to create central user-friendly dashboards as part of the larger digital transformation. These dashboards capture and visualize data efficiently, providing real-time insights for quick decision-making.
A holistic approach with Siemens Xcelerator
Carlsberg needed a holistic digital strategy. With Siemens Xcelerator, Carlberg bridged the real and digital worlds, enhancing quality and ensuring compliance — making every step from field to glass smarter and more sustainable.
Powering digital brewing
Brewing an ingenious solution
Siemens developed an ingenious solution to eliminate manual intervention, improving accuracy, consistency and transparency. The system maintains digital brew and filtration cards on a batch-wise basis for historical analysis and trend identification. It streamlines workflows and enhances data integrity and traceability. Operators gain real-time insights, enabling informed decision-making and prompt responses, including the identification of golden batches. Management benefits from insights into process performance and efficiency, while SMEs can access real-time data remotely to review brew quality and historical info at any time. The system also supports automated mailing of brew and filtration cards to key stakeholders, ensuring continuous communication and transparency.
The tech backbone: Powering digital brewing
The project's technical specifications included a high-performance software suite comprising WinCC V8.0 for SCADA, PM Server V7.4 for process management, PM Analyze V10.4 for detailed analysis, and MS Office Professional for documentation and reporting. WinCC V8.0 offers intuitive access to crucial process knowledge, enabling efficient and informed decision-making. PM Addons 10.4 provides advanced analytics and visualization tools, supporting comprehensive process monitoring and optimization.
Batch-wise logging and reporting
To further enhance process monitoring, Carlsberg collaborated with Siemens to implement batch-wise data logging for critical parameters. This data is then used to generate digital brew cards and fermentation charts, mapping data to process monitoring trends. This approach not only improved accuracy but also provided a comprehensive history of the brewing and fermentation processes. The digital brew and filtration cards are maintained on a batch-wise basis for historical analysis and trend identification, streamlining workflows and enhancing data integrity and traceability.
Brewing the future: Realizing Carlsberg’s vision
As Carlsberg continues to innovate, the tangible benefits of this digital transformation that the company implemented with Siemens technology are becoming evident. The implementation has increased brewing batches with live time monitoring of each brew, reduced steam consumption by 0.2 KWH per HL, and saved 200KW of power per month. Brewers can use the system's golden batch prediction as a reference for future batches, ensuring consistent quality. Live tracking of all the Unitanks provides information on the fermentation stage, and the system promptly addresses any deviations in parameters. The lean manufacturing system maintains historical data for one year, helping the Brewmaster improve processes and track customer complaints.
“Partnering with Siemens has been a game-changer for Carlsberg India. Their domain expertise and advanced easy to adapt solutions have enabled us to seamlessly integrate our brewing and filtration processes, automate data collection, and enhance real-time monitoring. As a result, we've achieved significant improvements in operational efficiency, data accuracy, and resource utilization.”