CIP Automation & Monitoring for Breweries

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1 CIP Automation & Monitoring for Breweries March 17, 2016 Adam Friedler

2 Agenda Automation Opportunities Automation for CIP monitoring & optimisation Case Histories Questions

3 GOAL OF AUTOMATION IS UNCOVERING OPPORTUNITIES BREWHOUSE UTILITIES Filtration CELLAR Filter Crate washer Bottle washer BOTTLING HALL Filler Pasteurizer

4 BREWERIES ARE IN CONSTANT MOTION for CIP Ongoing Operational Pressures Data Overload Labor Availability Standardizing Processes Balancing & Prioritizing Activities Troubleshooting Quality Issues

5 CIP SIGNIFICANTLY IMPACTS OPERATIONS AND IS DIRECTLY RELATED TO CORPORATE DRIVERS BRAND PROTECTION Product Safety & Quality COMPLIANCE WITH REGULATIONS Validation Support OPERATIONAL EFFICIENCY Cleaning Time Optimization SUSTAINABILITY Water Savings Energy Reduction Water Treatment PRODUCT INNOVATION New Product C&S Support

6 CIP LEADERSHIP JOURNEY Next step on our CIP evolution DT CIP 80s 90s Sanitizer innovation (Peracids) 1973 First spray ball 1957 First CIP single use

7 WHAT IS 3D TRASAR TM CIP? 3D TRASAR CIP is a constant CIP optimization program that uses advanced sensors that monitor traced chemistry providing process visibility with actionable data supported by Ecolab service and industry leading expertise. Plant Instruments Advanced Sensors Proprietary Chemistry Ecolab CIP Experts Process Visibility & Action

8 HOW DOES IT WORK? Valves/Pumps Analog Signals Chemistry Sensors I/O and MES Secure analytical and reporting portal PLC Network Local Server (SmartBox) Meters/Sensors Digital Signals OPC Server Historian Database Secure web access to customized monitoring and analysis portal

9 WHAT ARE THE OUTCOMES? for CIP Monitors CIP systems 24/7/365, safeguarding CIP quality, total cost and process optimization by: Establishing consistent CIPs for each object/circuit Tracking each CIP against its optimal CIP profile Flagging deviations that may impact product quality and efficiencies Identifying optimization for quality & cost Providing benchmark performance to SOP s & between systems

10 WHAT DOES THE OUTPUT LOOK LIKE? for CIP 1 Resource Consumption

11 WHAT DOES THE OUTPUT LOOK LIKE? for CIP 1 Resource Consumption Change to last 7 or View a different last 28 days facility View 10-day trends for each resource Electricity consumption in last 24 hours Electricity consumption vs. the previous 24 hours

12 WHAT DOES THE OUTPUT LOOK LIKE? 2 Top Consuming Washes

13 WHAT DOES THE OUTPUT LOOK LIKE? 2 Top Consuming Washes What equipment is using the most thermal resources? Drill down to understand why cost is so high Quick links to view CIP run report and chart

14 WHAT DOES THE OUTPUT LOOK LIKE? 3 Wash Summary and Identifying Deviations

15 WHAT DOES THE OUTPUT LOOK LIKE? 3 Wash Summary and Identifying Deviations Drill down for Detail on the Deviation Quick links to view CIP run report and chart What Deviation is occurring? Do I Need to Know Immediately?

16 OPERATIONAL EFFICIENCY European Brewer Case Study CIP automation helped a brewer achieve exceptional hygiene procedures while realising significant operational savings. REDUCED ENERGY USAGE REDUCED WATER CONSUMPTION FOR STERILIZATION TOTAL ECONOMIC BENEFIT Ecolab s 3D TRASAR CIP Technology provided a major European brewer with the technology it needed to achieve its Golden Hygiene Plan while reducing costs and driving continuous improvement. SAVED approx. $4,900 pa SAVED approx. $42,700 pa SAVINGS Over $110K (After Two Months)

17 CASE STUDIES for CIP High Temperatures Situation: 3DTRASAR for CIP shows that temperatures for caustic and sterilization cycles consistently exceed the stated set points Caustic: feed temp 85C, return temp 75C Sterilization: feed temp 92C, return temp 80C Opportunity: Reduce temperatures to optimal range Caustic cycle showing a return temperature of C should be no more than 75 0 C Solution: Optimized temperature programming to save energy Established tighter range for exception reports to monitor the change Sterilisation cycle showing a return temperature of C should be no more than 80 0 C

18 CASE STUDIES 3D TRASAR CIP Analysis: Sanitizer pump fired, but no sanitiser signal detected indicating several possible scenarios (empty drum, sensor not working, cracked tubing etc) This occurred for a number of washes before resolution 2 nd chart demonstrates 3D TRASAR sanitiser signal verified Ability to set sanitizer concentration Exceptions and Notifications No Sanitiser Signal 3DT Sanitiser Signal Verification Pump signal activated No traced sanitiser signal Pump signal activated Traced sanitiser signal

19 CASE STUDIES Hot Water not Recirculated SITUATION: During sterilization of yeast storage vessels, 3D TRASAR for CIP found that hot water was pumped to drain and not recirculated 141 hl per wash sent to drain OPPORTUNITY: Recirculate hot water to capture savings SOLUTION: Recommended improvements to water management in the vessel to ensure correct flow rates achieved Improvements enabled the hot water to be recirculated around the vessel Alternative solution: replace hot water with PAA Estimated annual savings: $30,714 $46,750 Assuming 48 cleans/week

20 CASE STUDIES Safety & Energy Cost Avoidance SITUATION: High start-up temperatures during all CIP cycles $7,000 $14,000 OPPORTUNITY: Avoid early equipment replacement Save energy Prevent scalding incident Fact Summary: $15,000 Total: $36,000 SOLUTION: Account Manager confirmed high temperatures at source Plant to replace leaking valve On going notification to prevent future incident Supply Temperature Return Temperature CIP Inactive CIP Active

21 CASE STUDIES Product Quality issue IDENTIFIED SITUATION: Investigation of wash water consumption deviation found operator skipped the pre-rinse on the wash of Tank 8. OPPORTUNITY: Carry over of heavy soils into wash will prevent effective wash SSOP Compliance SOLUTION: Supervisor trained Sunday operator with Wash Summaries. New Exception for extended rinse phase AND low volume could indicate improper CIP connections. Training 3D TRASAR(TM) for CIP Diagnostics System Notification: "Rinse" Phase, between steps 3 and 5 for this object was less than 4 minutes or under 400 gallons 3D TRASAR TM for CIP Diagnostics System Notification

22 CASE STUDIES Proper Rinsing 3 Burst Rinses Skipped

23 CASE STUDIES CIP automation helped dairy achieve consistent Clean-in-Place performance and consistently high quality product REDUCED CHEMISTRY FOR CLEANING CONSERVED REDUCED WATER CONSUMPTION FOR CLEANING CONSERVED REDUCED CLEANING TIME SAVED 3,000 gallons 963,750 gallons 1,295 hours Generally 10 to 20% reductions in CIP operating costs seen. Results vary based on current state of CIP system and SSOP compliance.

24 SUMMARY CONSISTENCY & OPTIMAL SYSTEM PERFORMANCE Plant Quality Assurance Production & Operations Engineering & Maintenance Visibility to leading indicators of product quality; manage exceptions to SSOP; faster root cause analysis Manage and reduce CIP time; reduce risk of product loss due to improper CIP; data driven projects to reduce costs Identify equipment malfunctions; protect assets from unneeded wear; direct PM resources to problem areas Corporate Quality Real-time visibility to plant SSOP conformance; automatically track improvement over time; reduced risk of quality incidents Real-time visibility of consumption metrics; trending reports over time; identification of largest resource drains Sustainability

25 Thank You. Questions?