Krombacher Brewery chooses OTAS™ 7 from GEA as new automation system
In 2009, after a thorough market analysis, Krombacher Brewery placed an order with GEA Brewery Systems for the complete conversion of the automation system to OTAS™ 7 in all cellar and filling areas.
The two companies had already cooperated before. In 1989, Tuchenhagen Brewery Systems – today part of the GEA Group - supplied a large fermentation block with corresponding CIP plant and OTAS™ MD control as the first completely automated cellar area.
New automation system on trial
15 years after introducing OTAS™ MD, it was high time for the brewery to modernize the operator stations based on 16 MHz processors and to replace the Siemens S5 automation units, which have been discontinued. A case for GEA Brewery Systems. However, it was not sure right from the beginning that the brewery would choose a solution from Büchen. Various automation systems from different suppliers were thoroughly tested in a systematic market analysis. This orientation phase lasted several years and finally, the current OTAS™ 7 software from GEA convinced the brewery mainly with its great flexibility.
No doubts with OTAS™
Today, OTAS™ (Open Technology Automation Solution) consists of networked modules – like fermentation control, program operation, recipe generation, curve recording, reporting and plant visualization. A common visualization software is combined with these modules to form an automation system. OTAS™ 7 has always been compatible with earlier versions of OTAS™. Advantage: the current hardware and software are also compatible with existing automation units and their existing programming.
Furthermore, the clever system architecture of OTAS™ 7 allows to replace the iFIX by Intellution - which was used first - by Siemens WinCC as basis for the automation. It was also a decisive advantage that Krombacher could modernize the operating level first and that the existing S5 automation units could be left unchanged for the time being, but could already be controlled with OTAS™ 7.
Five years of conversion without production downtimes
After some new plant components at Krombacher had already been provided with OTAS™ 7, the strategic decision was made in 2009. GEA Brewery Systems was awarded the contract for the complete conversion of the automation system to OTAS™ 7 in all cellar and filling areas.
In total, 14 of the old S5 units will be replaced by nine modern S7 automation units. It will then be possible to access all plant components from each of the 26 operating stations. Redundant servers in all areas provide maximum production safety.
There are only two periods per year, in the low season of beer production, when commissioning work can be performed. In the meantime, the conversion of some plant components has been successfully completed. It is particularly noteworthy that all conversion work was carried out without impairing the production.
