By: Aaron Ganick, BrewOps
Brewery equipment is expensive and must be carefully maintained. Downtime is even more expensive. That’s why brewers are searching for ways to streamline operations, compile useful data, and keep eyes on their critical equipment 24/7.
In the recent past, small- to medium-sized craft breweries relied on pen and paper methods for record-keeping and data collection. Only the largest breweries had access to real-time, actionable sensor-based intelligence. But even then, the automated intelligence was expensive, inflexible, and difficult to modify. The craft brewing industry requires technology that matches its creativity and ingenuity—automation that is intuitive, nimble, easy to install and use, and solves real problems that all brewers face daily.
With a streamlined ecosystem and affordable sensor technology, even the smallest breweries can automate their equipment in a day and immediately receive critical benefits like reducing purge times, increasing operator and product consistency, preventing chiller failure, monitoring glycol temperatures entering and exiting the chiller, preventing product loss, and monitoring dissolved oxygen levels at any part of the brewing process—all while receiving alarms and notifications that save the brewing operators from an unexpected bad Monday morning.
The benefits of implementing automation in a brewery environment are numerous. Here are the top 10 reasons to use sensor technology to enhance various aspects of the brewing process.
1. Ease of Mind: When it comes to monitoring crucial equipment throughout the brew house, sensor technology provides confidence that the utilities are acting the way they should. When anything goes wrong, operators receive instant notifications so they can react as quickly as possible with a minimum amount of downtime or disruption to the product. Automation provides “eyes on the equipment” 24/7 and allows operators to focus on the myriad of other responsibilities throughout the facility.
2. Actionable Data and Insight: Sensor technology provides a communication methodology that enables long-range and high-speed data transmission from sensors to either a mobile app for local access or to a gateway that relays information to a cloud-hosted solution viewable from anywhere in the world. For example, vibration sensors notify operators if a motor is failing and requires service.
Temperature sensors provide alerts when critical processes deviate from set parameters, and pressure sensors arm operators with essential tank level and utilization data. By continuously monitoring and analyzing data on variables such as fermentation gravity and pH, brewers can optimize processes to improve the quality and consistency of future batches. Additionally, monitoring purge gas usage and CIP water waste helps reduce consumption and costs, enhancing both efficiency and sustainability.
3. Ease of Installation: Sensor technology is plug-and-play, requiring no IT support or complicated systems integration. Installation takes only a few minutes, and sensors start delivering data immediately once they are digitally activated. Modern sensing technology is extremely rugged, does not require professional installation, and requires minimal space. Additionally, they are battery-powered with a replaceable, long-lasting industrial power source.
4. Ease of Use: The technology is sophisticated yet simple to use, requiring minimal training. It enables brewery operators to quickly respond to alerts and make necessary adjustments to ensure equipment efficiency and product consistency. The user-friendly interface allows operators at any skill level to monitor and manage processes effortlessly, ensuring smooth operations and high-quality production standards.
5. Time, Money, and Downtime Savings: Brewery equipment is expensive and must be carefully maintained, but downtime can be even more costly. Alerts enable operators to take appropriate actions to keep systems operational. Reduced tank purge time saves money and decreases CO2 consumption.
Consistent steam production from the boiler significantly impacts beer quality in the brewhouse. Sensor technology ensures consistent fermentation temperatures, which can be challenging to maintain in the cellar. A failing chiller can cause rising temperatures that lead to off-flavors, off-aromas, and potentially wasted batches of beer that are unable to be sent to packaging. Some brewers report that an unnoticed chiller failure can result in the loss of a thousand gallons of beer.
Automated systems optimize the use of energy, water, and raw materials, reducing waste and lowering the brewery’s environmental footprint.
6. Consistency and Quality Control: When each batch of beer is brewed under consistent conditions, variability is reduced and high-quality standards are maintained. Sensor technology provides granular data that ensures that the quality of the final product is controlled. Automation enhances precision in timings, temperature, and other variable measurements to ensure that ingredients are added at the right moments in the correct quantities—which is crucial for achieving the desired flavors and aromas of craft beer.
7. Efficiency and Productivity: Automated systems streamline the brewing process. This leads to higher production rates, brewery tasks to be completed more efficiently, and the ability to meet growing demand without compromising quality. Significant cost savings with regard to wages and associated expenses can be realized by automating repetitive and labor-intensive manual tasks.
8. Improved Safety and Regulatory Compliance:
Automation is crucial to reducing the risk of human error and minimizing exposure to hazardous conditions. For example, the Clean-in-Place process that is used on most brewery equipment can be automated to keep workers less exposed to boiling hot water and harmful chemicals. Sensor technology also helps to ensure that brewery operations comply with industry regulations and standards by maintaining accurate records and consistent practices.
9. Innovation and Adaptability: Automation enhances the creativity and ingenuity that already exists in the brewing industry. Brewers can quickly implement new techniques and recipes with flexible automation that allows them to experiment with different styles and flavors.
10. Scalability: Even the smallest brewers can automate quickly and inexpensively by utilizing sensor technology. One sensor on one piece of equipment can be an immediate game changer. Breweries can scale up as significant savings are realized through more efficient processes and reduced downtime. Automated systems can be adjusted to handle larger volumes without the need for extensive manual intervention.
The Value of Brewery Automation
Sensor technology does more than just solve problems—it helps to anticipate problems before they occur. It provides flexibility and agility to the brewing process. With automation, breweries can achieve greater efficiency, consistency, and quality while also enhancing safety and sustainability in their operations.
Automation and sensing technology are now accessible to all breweries. Fast and easy-to-install systems can get brewers up and running quickly, even for older infrastructure that was designed with “day one” operation in mind and not the future. All types of brewing equipment can be easily and affordably outfitted with sensor technology.
These sensors can reduce total capital expenditure while also minimizing waste streams. Most importantly, from day one, actionable data provides real results to solve problems, benefiting even the smallest breweries.
About the Author
Aaron Ganick is a serial technology entrepreneur and the founder and CEO of Preddio Technologies, the parent company of BrewOps. Aaron holds a degree in electrical engineering from Boston University and has authored dozens of granted patents in the fields of optical networking, telecommunications, and automation systems. He can be reached at aaron.ganick@brewops.com. For more information on BrewOps, the fast and easy-to-install brewery automation platform. For more information please visit www.brewops.com
