Food & Beverage: Virtually brewing

When the Paulaner brewery in Munich decided to relocate its operations from the Nockherberg to Langwied, every aspect was thoroughly planned in advance. To ensure that the set-up of the new brewing site would go smoothly, Paulaner relied on the Tecnomatix simulation tool.

Paulaner brewery, Germany

– Apart from the actual construction, many factors can affect processes when designing a brewery and thus impact the design of both production and logistics – for example, continuously changing product lines, strong seasonal demand fluctuations, and changing packaging and bottles. Different recipes for the intermediate and final products as well as the technical specifications of brewing kettles, tanks, filters, and filling lines for various types of packaging require sophisticated technical solutions.

The Paulaner brewery has been brewing beer at the Nockherberg since 1634. It is the only brewery in Munich still operating at the original location, but by now it has reached its capacity limits. Therefore, on June 3, 2014, the foundation for a new brewery was laid at a 15-hectare site in Munich-Langwied. The new facility will take up operations in 2016, but brewing has already gotten under way – though only virtually thus far. As an integral part of the construction plan for the new state-of-the-art brewery, Siemens developed a solution for the beverage industry in cooperation with iSILOG, a leading service provider for simulations. The solution uses Plant Simulation software from the Tecnomatix portfolio provided by Siemens PLM Software.

The simulation model, which comprises brewery-specific components such as the brewhouse, fermentation and storage tanks, filters, pressure tanks, filling lines, and storage enables simulation of the entire production process. As a result, various planning strategies and scenarios can be assessed in advance.

Design scenarios for capacity and performance

The data for the simulation model are entered into standardized Excel spreadsheets. Inputs regarding customer demands and process step parameters (brewing, fermentation and storage tanks, filters, pressure tanks, bottling, storage) are structured with the help of various tabs. Additional tabs allow users to define tank capacities in terms of number and size as well as the availability of filling lines for multiple process steps. After the data are imported into the simulation software, the model components are automatically generated and configured – without the need for detailed knowledge of the simulation model architecture. As a result, various scenarios can be simulated, analyzed, and compared to other scenarios in a very short time. Stochastic processes such as these allow Paulaner to assess the various impacts of products, processes, and customer demands, even potential malfunctions, in order to determine needed tank and equipment investments. Planning for the new Paulaner brewery also called for the optimization of other performance parameters such as heat demand and electricity and water consumption as well as beer loss during the brewing process.

With the help of the model and specific simulation scenarios, various improvement measures can be tested and compared. Only those measures that actually prove to be successful are eventually implemented. As a result, poor investments can be avoided. The Plant Simulation software enables brewing experts to identify bottlenecks and develop ideal strategies for cleaning, retooling, batch sizes, production planning, and control. The essential result is a new sequencing strategy regarding the product mix and quantity.

Ready for start-up

With simulation, various performance, flexibility, and cost objectives can be viewed together. The Plant Simulation software also enables strategic planning several years in advance, because decisions concerning new investments and optimization measures with respect to future needs and product offerings can be simulated and analyzed in detail. With this solution, Paulaner brewery is well equipped to keep things flowing smoothly at Oktoberfest 2016.

Tecnomatix software from Siemens PLM

Advantages provided by the Tecnomatix production simulation and validation solutions:

 

  • Early detection of suddenly occurring system faults as well as more cost-efficient and easier troubleshooting
  • Reduced system start-up time through minimized need for physical tests
  • Precise quantification of manufacturing process and production throughput changes
  • Easier implementation of technical studies
  • Connection to the automation simulation with Simit Simulation Framework (via OPC interface)

Picture credits: Paulaner/sampics; iSILOG/Paulaner

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