GEA Process Automation Solutions: Diversity A natural advantage also in process control engineering.

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1 GEA Process Automation Solutions: Diversity A natural advantage also in process control engineering. engineering for a better world GEA Process Engineering

2 Automation and process control systems for breweries. 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 industryspecific 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. 2

3 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: Program structure according to S88 Control of continuous and batch processes Short cycle times thanks to the "time-slice" technique Simulation of all peripheral modules GEA equipment modules (MLM, IWM, etc.) Innovative object classes (addressless programming) Instance concept (freely selectable and changeable peripheral addresses) Optimized PID control algorithm 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. GEARBOXX MES functions based on SQL data base GEARBOXX Reporting (web-based) GEARBOXX Trending GEARBOXX Process control system based on PC platform with Iltis or Panel IPC GEARBOXX Dialog GEARBOXX Sequence GEARBOXX Recipe Manager GEARBOXX Event GEARBOXX Language GEARBOXX MLM GEARBOXX IWM MES PCS GEARBOXX XLS GEARBOXX S7 3

4 User-friendly control systems. 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. OTAS Interface manager (ERP/LIMS) ERP OTAS MES functions based on SQL data base OTAS Report (web-based) OTAS Monitor OTAS Process control system based on WinCC, InTouch, ifix or Iltis OTAS Dialog OTAS Sequence OTAS Combine OTAS Event OTAS Language OTAS Config OTAS S7 RDBMS SQL MS/Unify OTAS MLM OTAS IWM OTAS Fermos OTAS Service OTAS Energy OTAS DFM OTAS Brand MES PCS 4

5 OTAS includes: OTAS Dialog consistent, clear and reliable plant operation and visualization. OTAS Sequence & Combine recipe-based sequence control including operator dialogs for manual intervention. OTAS Event log of all automatic activities and manual interventions. OTAS Language online language switching. Thanks to Unicode, Cyrillic or Asian characters are not a problem. Optional modules: OTAS Service preventive maintenance, maintenance logs and spare part ordering. 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. OTAS Remote secure encrypted connection to our service team at any time via the internet. 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. OTAS Monitor current curves, reference curves and individually configurable views enable an evaluation of the process. 5

6 Monitored brewing through automation. 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. 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. 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. 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. FACTS & FIGURES: Many years of experience in the brewing industry characterize our automation solutions and the know-how of our engineers As integration specialists, we combine our knowledge of process and plant engineering with the hardware and software products of the market leaders We offer software modules that have been developed in accordance with the specific requirements of brewery automation and optimized together with our customers More than 500 automation specialists are working in the GEA Process Engineering segment. BRAUMAT MES functions based on MS SQL data base BRAUMAT Reporting with MS SQL Repor BRAUMAT Process control system BRAUMAT Logging and archivin BRAUMAT Trending BRAUMAT Graphical recipe syste BRAUMAT Maintenance function BRAUMAT Diagnostics functions BRAUMAT Language 6

7 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. twriter g m s BRAUMAT Interface to SIMATIC IT brewmaxx Visu-Recorder BRAUMAT Order system BRAUMAT Route Control MES PCS brewmaxx Integrate MES functions brewmaxx connect Interface manager brewmaxx Process control system with recipe management brewmaxx Messenger brewmaxx Equipment Modules brewmaxx material Process-oriented materials management brewmaxx Visu-Recorder brewmaxx Routing Management ERP MES PCS 7

8 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. GEA Process Engineering GEA Brewery Systems GmbH Huppmann Tuchenhagen Locations: Heinrich-Huppmann-Str. 1, Kitzingen, Germany Phone , Fax Am Industriepark 2 10, Büchen, Germany Phone , Fax gea.com, GEA Process Automation Solutions.E / GEA Brewery Systems GmbH / All rights reserved / Subject to modifications / Printed in Germany