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2022 Project Finalist

Wunderlich-Malec Engineering, Inc.

Project For: Stone Brewing Company

 

Improved SCADA, HMI, and MES for Ninth-Largest Craft Brewer in United States

 

PROJECT SUMMARY:

Stone Brewing is the ninth-largest craft brewing company in the US, located in Escondido, CA, and was founded by Greg Koch in 1996. The goal of the project was to upgrade the existing Siemens BRAUMAT brewing automation system with a new design consisting of Rockwell PLCs, networks, Ignition HMI, historian, batch, and MES software for the two brewhouses at Stone Brewing Company in Escondido, California. 


 

PROBLEM:  

The existing Siemens BRAUMAT system was challenging to support and made recipe and batch changes difficult.

 

SOLUTION:

Wunderlich-Malec Engineering provided Stone Brewing with design, engineering, hardware, software, networking, programming, and support for upgrading the existing Siemens BRAUMAT brewing automation system at Brewhouse 1 and 2 at Stone Brewing Company, and used an Ignition Hub & Spoke architecture. 

Ignition Perspective and Sepasoft’s Batch Procedure Module were key to this project, ensuring fast and reliable access to manufacturing data and secure communication. Ignition was used as a uniform HMI following ISA 101 and High Performance HMI guidelines. ISA-S88 methodology was implemented for batch processing.

 

RESULTS:

Perspective’s mobile-responsiveness gives access to historical data in any location, helping brewers to make informed decisions in any given circumstance. The batch engine was integrated into the HMI screens, so entire systems can be operated and adjusted intuitively from a single interface. This project has sparked even more ideas for future expansion of Stone Brewing’s automation systems.

 

DEPLOY DATE: January 2021

Project Scope:

  • Tags: 100,000
  • Screens: 44 screens, 60 Faceplate (Perspective)
  • Clients: 4
  • Alarms: 512 (configurable)
  • Devices used: 2 ControlLogix 85E
  • Architectures used: Hub & Spoke
  • Databases used: 2 databases, SQL Server 2016 Enterprise
  • Historical data logged: 159 historical process tags

Presented By:

Fred Zaboli

Fred has 20-plus years of experience with automated control systems ranging in size and various industries with knowledge of a wide range of SCADA, HMI, DCS, PLC, SIS, and network systems. He has worked in Pharmaceutical, Food, and Beverage (Brewing), Power, Oil & Gas, and Water and Wastewater industries with owner and engineering companies.

Created By:

Wunderlich-Malec Engineering, Inc.

(WM) is a 500 plus employee-owned EPC Firm specializing in Electrical and Control Systems Engineering and Integration Services. We have active projects across most vertical markets, including Pharmaceutical, Food, Beverage (Brewing), Material Handling, Manufacturing, Energy, Entertainment, Oil, Gas, Pipeline, Chemical, Semiconductor, and Water industries. Wunderlich-Malec originated in the Minneapolis/St. Paul area, and has been in business since 1981. As an employee-owned company, we focus on strong partnerships with our customers. We design each project approach to suit the customer's needs and build strong teams through our diverse range of expertise.

Website: wmeng.com

Project For:

Stone Brewing Company

Founded by Greg Koch and Steve Wagner, Stone Brewing Company has come a long way since opening in San Diego County in 1996. Now the ninth-largest craft brewer in the US, Stone Brewing operates two production brewing facilities on both coasts, in Escondido, CA and Richmond, VA. Today, their beer is available in all 50 states and more than 40 different countries. But they don't just brew beer, they also take great pride serving it at their restaurants and tap rooms! stonebrewing.com

Industry:

Food & Beverage