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brewmaxx
Developer(s)ProLeit AG
Operating systemWindows
LicenseProprietary commercial
Websitewww.brewmaxx.com

brewmaxx is a process control system for the brewing industry. The various process steps of a brewery can be automated, controlled and monitored via the software components of the brewmaxx range.

Fields of application

Due to its scalability, brewmaxx is suited to applications ranging from single station to multi-server systems. It is used in:

  • small breweries (up to 100 hectolitres per annum)
  • medium-sized breweries (up to 1 million hectolitres per annum)
  • large breweries (more than 1 million hectolitres per annum)

The main fields of application include the automation of breweries (see brewery) and/or fermenting and storage cellars. Also a complete automation of all the production areas of a brewery (e.g. at Warsteiner Beer and Brewery) - from raw material intake to filling - can be realised with the brewmaxx process control systems. The “small” control system, brewmaxx compact, has been available for individual production areas, e.g. ancillary plants, water treatment, filter or CO2 plants as well as small and medium-sized breweries, since the middle of 2010.

The basic systems and modules of brewmaxx are generally used for the automation of new plants and for migration projects. Existing, outdated control systems with a structured software design can be migrated to brewmaxx via conversion tools.

brewmaxx is used as teaching system for process control technology for breweries at the Technical University Munich (TUM). Various university projects use brewmaxx as process controlling system[1].

Architecture

The brewmaxx range is based on an integrated client-server model and basically uses standard Microsoft software. The architecture has a modular design. Depending on the requirements, the modules can be used individually or in combination for process control, Data acquisition (PDA), process management, production management and ERP level integration (see Enterprise resource planning).

Modules

brewmaxx material

brewmaxx material is a process-oriented material management system, offering a precise ‘per transaction’ online view of all material movements, which are recorded on the basis of a bespoke storage model. Besides inventory management, the acquisition of this information also enables research, statistical evaluations and batch tracking. The basic system brewmaxx Liqu iT can be seamlessly extended with the brewmaxx material module for order and recipe-controlled production processes.

brewmaxx integrate

The brewmaxx integrate module records process-relevant information from different plants and process areas and enables their division-independent integration with regard to information management. The reporting component of brewmaxx integrate works with web-based clients, i.e. access is possible without installation and the availability of a brewmaxx client. This way, workplaces which are not directly connected to the process (e.g. plant manager) can be integrated in the entire system.

brewmaxx connect

The brewmaxx connect module is a freely parameterisable interface for universal data exchange between brewmaxx systems and various third party systems. These include client/server or host-based systems, e.g. ERP, LIMS and maintenance systems, but also intelligent measuring and analysis instruments (e.g. inspectors and weighing systems). For each of the interfaces implemented with brewmaxx connect, the system offers a detailed online diagnosis which allows the further analysis of communication processes.

Product features

brewmaxx has been designed as a multi-lingual system. At application level, it offers a computer-dependent language changeover option for the user interface and can be configured in several languages. Communication takes place via the Ethernet connections TCP/IP and OPC.

The standard system is supplied in German and English. Russian and Spanish are available as an optional, preconfigured language package.

OPC (see OLE for process control) is preferably used as the interface; however, various OPC servers might be used depending on the control units to be integrated. Furthermore, a driver-based interface is available for non OPC-capable systems. This ensures simple and flexible integration of numerous control systems, e.g. from Mitsubishi Electric, Allen-Bradley, Siemens, VIPA and others. brewmaxx Acquis iT can be used for production data acquisition as a stand-alone solution and in combination with an existing basic brewmaxx system. Reporting functions enable selective access to recorded process and material data.

Standards

Production data acquisition with brewmaxx Acquis iT is based on the Weihenstephan Standards[2]. In cooperation with industry representatives and with the support of Wissenschaftsförderung der Deutschen Brauwirtschaft, the chair of Food Packaging Technology at the Technical University Munich in Weihenstephan has developed a standard for the connection of BDE systems to bottling plants.

The standard includes the uniform provision and structure of data from the control units of various manufacturers. The Weihenstephan Standards 2000 comprise the guidelines for standard BDE specifications for bottling plants; the Weihenstephan Standards 2005 describe the interfaces and data provision for bottling and packaging plants in the beverage industry.


Archiving

Archiving of process values takes place via MS SQL databases. Older files are transferred from the production database to an archive database to ensure sufficient storage space for continuous data acquisition. At the same time, the data volume in the production database is limited and quick access to the database guaranteed. Data from the archive and production database are available for evaluation purposes; the research tools automatically access both areas.

User interface

Process images are created via Microsoft development environments. The standard system offers a library of process image controls for process data visualisation, which can be extended user specifically. A process image wizard has been integrated for process image creation.

User management

The user management enables the configuration of a hierarchical authorisation system via which access rights are assigned to different users and user groups. The user management is integrated in the comprehensive parameterisation tool - the “Configuration Client”.

Reporting

The brewmaxx reporting functions support division-independent, configurable reporting. The Report Designer enables selective access to recorded process and material data. The acquired data is, e.g., available as brew or tank reports.

Engineering

During plant planning, the generation of program codes is generally replaced by parameterisation and data download (object data records). All brewmaxx system modules have a central engineering environment with a common database and logical user interface for intuitive parameterisation - the “Configuration Client”.

Message system

The message system is part of the monitoring function. All messages are recorded in a central database; the messages can be configured in several languages. Certain messages can be selected via filters; several message lines can be displayed with different filters.

Measured values

Numerous measured value views can be graphically displayed as a curve or binary trace. The configuration of the measuring points takes place in the Configuration Client.

Visualisation & troubleshooting

The visualisation data of certain automation classes can be recorded with the add-on brewmaxx Visu-Recorder. This application records processes similar to a VCR and outputs them directly in the process image. The output speed can be selected here. The Visu-Recorder is mainly used for troubleshooting in case of complex processes.

Application & distribution

Brewmaxx has an install base that includes German breweries Erdinger, Oettinger, Warsteiner, and others. Internationally, the system is utilized by brewers including Anheuser-Busch, Heineken, Carlsburg Group, and Tsingtao.

History

The predecessor systems of the brewmaxx platform already provided the technological functions (TF) for brewery-specific requirements. The big brother of brewmaxx is the process control system Plant iT, developed and distributed by ProLeiT AG. Plant iT is the industry-independent solution for the following areas: food & beverages, dairy industry, feeding stuff, pharma & chemical industry, biodiesel & bioethanol. In many areas, it is identical to the brewmaxx components, but additionally comprises an ISA 88 compliant batch system (see Batch_production).

The software has been distributed and continuously further developed under the name brewmaxx since 1997.

References

  1. ^ Technical University Munich, Lehrstuhl für Lebensmittelverpackungstechnik: Fully automated mini-brewery
  2. ^ Weihenstephan Standards
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