There was a time when enterprise resource planning (ERP) systems were considered to be a justified expense only for those at the very top of the revenue scale, but the consolidation of the beverage manufacturing sector coupled with the fast pace of technology has created a demand for elegant, integrated IT solutions for beverage operations of all types. And suppliers are stepping up to the plate with customizable and affordable solutions.
Rockwell Automation (Milwaukee, WI) has introduced an automation software package designed specifically for brewhouse applications. The new system, aptly named Brewhouse Solution, integrates control, information, implementation and support into a single package. The intent is to allow brew masters to better manage their operations, improve throughput, reduce waste and decrease operating costs. The solution is based on Rockwell's Integrated Architecture System, which includes the Logix Control Platform and the FactoryTalk integrated production and performance suite.
"Consolidation, mergers, acquisitions and the focus on brand management increase the need for brewers to concentrate on production flexibility, agility and efficiencies in their production operations," says Mike Jamieson, beverage industry vice president for Rockwell Automation. "The Brewhouse Solution is designed to help brewers better monitor and control their production processes and standardize on a common solution across multiple facilities for improved operations and consistent product quality."
The solution was designed after analyzing the typical process and activities in today's breweries and with input from former brew masters and technical managers.
Although freshness dating is en vogue for all manner of consumer goods these days, in the business of milk processing, freshness is essential. A comprehensive ERP solution can help to optimize inventory ordering and handling, ensuring freshness and improving efficiencies. When Denmark's Arla Foods, the largest dairy processor in Europe, refurbished its Christiansfeld Dairy plant in 2002, the company selected an ERP system from Wonderware to provide full integration, traceability and visibility to its plant data, including inventory management and freshness.
The package installed by Lake Forest, CA-based Wonderware, a business unit of Invensys Systems, included the Industrial SQL server historian, InTrack resource tracking software, DT Analyst asset monitoring, OEE (overall equipment effectiveness) software and InTouch HMI.
The Industrial SQL server historian, which is based on MicroSoft's SQL server platform, collects data from industrial and business solutions throughout the plant, including individual PLCs from the plant floor. The data is compiled into a single database and the InTouch HMI application provides data visualization, giving managers a single go-to source for real-time performance metrics.
The Wonderware solution provides Arla with the ability to track and monitor quality issues as well as improve plant efficiency.
For fast implementation of an ERP solution in any sector of the beverage business, SAP offers the SAP ERP packaged solution for the beverage industry. Based on mySAP ERP and SAP Best Practices, the solution is designed for quick and easy implementation in medium-sized beverage operations.
The SAP system provides a single integrated platform that solves the problem posed by multi-vendor, heterogeneous IT environments created by mergers, acquisitions or systems that have been built off of legacy systems. SAP uses an open standard to facilitate future growth and the company reports that the system can be fully configured in as little as 16 weeks. The system includes a number of features customized for beverage applications, including track-and-trace for food safety compliance, a check-in, check-out function that records deliveries and returns, return/empties logistics, rebate and bonus management and excise duty management.
"Consolidation, mergers, acquisitions and the focus on brand management increase the need for brewers to concentrate on production flexibility, agility and efficiencies in their production operations," says Mike Jamieson, beverage industry vice president for Rockwell Automation. "The Brewhouse Solution is designed to help brewers better monitor and control their production processes and standardize on a common solution across multiple facilities for improved operations and consistent product quality."
