Automation and Software Solutions for Breweries

BRAUMAT is a modular Process Control System, developed by SIEMENS to fulfill the requirements of the Food and Beverage industries, specifically the Brewing Industry.

It is comprised by hardware (Industrial PCs and PLCs) and software components that have been carefully integrated, providing “out of the box” functionality that delivers outstanding benefits when compared to similar SCADA-based solutions.

“The BRAUMAT Standard” is the term commonly used to describe a set of system features, terminologies and software coding guidelines, which in turn define the functionality of a BRAUMAT Process Control System.  It has been designed to comply with the ISA-S88 international standard, and provides a common language for technologists, maintenance and software technicians to effectively communicate with each other.  This in turn allows for the efficient implementation of automation solutions, process improvements and ongoing system maintenance.

There are many reasons to use BRAUMAT.  Click here for a complete list of benefits.

Click here for a list of BRAUMAT’s main features.

BRAUMAT is comprised by the following main system components.  SIEMENS delivers these components as a pre-installed, pre-tested bundle, ready to start software engineering:

• IOS-Server (Information and Operator Station – Server).  This is a SIMAITC IPC series Industrial Computer from SIEMENS, which comes pre-installed with one BRAUMAT IOS-Server Software License.  Systems can be configured using only one IOS-Server, or using two fully redundant, hot-standby servers.
• IOS-Client (Information and Operator Station – Client).  This is a SIMAITC IPC series Industrial Computer from SIEMENS, which comes pre-installed with one BRAUMAT IOS-Client Software License..  IOS-Clients are optional, and are used to add more operator seats to the system.
• PCU (Process Control Unit).  This is one or more SIMATIC S7-400 PLC from SIEMENS, each of which comes pre-installed with one BRAUMAT PCU Software License.

In addition to the above hardware and software components, the following need to be added to the bill of materials depending on the scope of each project:

• Distributed I/O.  Although the PCU (i.e. the SIMATIC S7-400 PLC) accepts I/O Cards in its central rack and optional expansion racks, for most applications we recommended using Distributed I/O Modules instead.  These modules can be installed locally, nearby the actual instrumentation, and then connected to the PCU via just one PROFINET or PROFIBUS network cable.
• IOS Networking Components.  These are typically Industrial Ethernet components, including Ethernet Switches and Cables, used to interconnect the IOS-Servers and IOS-Clients.
• PCU Networking Components.  These are typically Industrial Ethernet components, including Ethernet Switches and Cables, used to interconnect the IOS-Servers and PCUs.
• Field Networking Components.  These are typically PROFIBUS or PROFINET components, including Switches and Cables, used to interconnect the PCU and Distributed I/O.
• Instrumentation.  Instruments are typically provided by the Machine Builder or OEM.

BRAUMAT comes in four different variations:

• BRAUMAT Lean.  Intended for smaller installations with plans to grow.  This is the most flexible starter option, with virtually unlimited room to grow as it allows seamless upgrade into a BRAUMAT Full edition.   It is comprised by one IOS-Server and one PCU, with an option to add additional IOS-Clients. Typical size is one Brewhouse production line, including Fermenters, CIP station and Yeast Tanks.  Can manage up to 40 Process Units per PCU, with a streamlined upgrade path to a BRAUMAT Full system.
• BRAUMAT.  Also known as BRAUMAT Full, this edition is intended for breweries that have outgrown the capacities of BRAUMAT Lean, or that require a redundant IOS-Server System.  This is the most flexible option, with practically unlimited room to grow.  Most of the breweries worldwide use the BRAUMAT Full edition.  Can manage up to 128 Process Units per PCU, with an virtually unlimited amount of PCUs.
• BRAUMAT Compact.  Intended for small-scale breweries, individual process areas or subsystems. Typical size is one Brewhouse production line, including Fermenters, CIP station and Yeast Tanks.  BRAUMAT Compact is based on the SIMATIC PCS 7 platform.  For new installations, BrauXp recommends the use of BRAUMAT  Lean or BRAUMAT .
• SIMATIC PCS 7 BRAUMAT.  Intended for breweries that are investing on the SIMATIC PCS 7 platform and the SIMATIC BATCH control engine, that require a high degree of customization and a rather strict adherence to validation according to 21 CFR Part 11.  It is also the option for those breweries that require PLC redundancy.  For new installations, BrauXp recommends the use of BRAUMAT  Lean or BRAUMAT .

The short answer is:  using third-party SCADA or HMI with BRAUMAT wouldn’t add any value.

As opposed to other solutions that use SCADA or HMI to visualize and change data in a PLC, BRAUMAT is a tightly integrated Process Control System which is based on PLC technology.  BRAUMAT software has two standard components:

• IOS Software.  This is the software component that runs on the IOS-Server or IOS-Client.  This software features standard HMI, Batch Control and Reporting functionalities, as well as a complete Software Engineering Environment.
• PCU Software.  This is the software component that runs in the PLC, and is written in native PLC code.  This software incorporates a standard library of Control Modules (e.g. software modules responsible for controlling valves, motors, PID controllers, etc.) and a full PLC-Based Batch Engine.  It also handles smart communication protocols between the PLC and the IOS-Server.

Since the interfaces to standard PLC software components are well documented, one could think of using third party SCADA or HMI to interact with the PCU Software.  Nevertheless, this would defy the purpose of using BRAUMAT as a highly effective and efficient engineering tool to solve complex process control problems.

Yes.  BRAUMAT offers the capability to run the recipe logic at the control level. The fact that BRAUMAT features PLC-Based Control Recipes is a key difference to other Process Control Systems based on a PC-Based Batch Engine, in that it provides increased reliability and faster control.

Once downloaded, the recipe will execute even without the need of the Recipe Server, which is crucial during server maintenance works during a running production. It also provides a totally problem-free recovery after power outages or system restarts, with no synchronization issues between the PC and the PLC.

Finally, the fact that PLCs are robust, industrial machines, designed for speed, makes them less prone to software glitches and ensures a lightning-fast system performance.