DrinkTank – for more digitalisation in the beverage industry

Beverages 4.0: An entire industry has to become more digital.

Hops, malt, yeast, water and … computer chips? In the past, four ingredients were enough to brew all the different types of beer. But times have changed: If you want to last on the beverage market today, you have to partly reinvent your business – and this also means making use of the benefits of digitalisation. 

Consumer trends and demands are changing faster and faster, production processes are becoming more complex, at the same time commodity prices are rising, legal regulations are becoming more stringent, and: more and more focus is placed on sustainability and environmental awareness. All in all, this results in a situation in which digital solutions and applications should not only be seen as an opportunity but as an indispensable necessity.

A network for more digitalisation: "DrinkTank"

But how can the digital revolution set foot in an industry that is typically rooted in tradition, such as the beverage and brewing industry? In response, Siegen university initiated the foundation of the so-called "DrinkTank", an independent network comprising the "SDFS Smarte Demonstrationsfabrik Siegen" (smart demonstration factory Siegen) as well as about a dozen renown companies and institutions. 

A strong network thrives on strong partners

DrinkTank attracted a number of expert partners. All of the participants either work directly in this industry, are service providers or are closely linked with the industry as equipment and (digital) system suppliers. 

• TUM School of Life Sciences, technical university of Munich
• Mensch und Maschine, a leading supplier of computer aided design, manufacturing and building
• Kaspar Schulz, the world’s oldest brewery equipment manufacturer
• VLB Berlin (Versuchs- und Lehranstalt für Brauerei), the research and teaching institute for brewing in Berlin
• Kieselmann Fluid Process Group, a conglomeration of companies in plant engineering and component manufacturing
• Krombacher, one of Germany’s leading premium breweries
• Micro Matic, market leader in the supply of keg couplers, fittings and draft dispensing units for the beverage industry
• ifm electronic, developer and producer of sensors, control systems, software and systems for industrial automation and digitalisation
• pmdtechnologies ag, the globally leading supplier of 3D image sensor technologies based on the time-of-flight principle
• Doemens, the private education and consulting institute for the brewery, beverage and food industries

KSB as a manufacturer of pumps and valves for all main and secondary processes in the beverage production plays a very central role in this network. On the one hand, KSB can contribute with its know-how gathered over many decades in this industry. On the other hand, KSB sees itself as a technological pioneer, especially in digitalisation. KSB has already got an entire range of digital solutions on offer, that have proved their worth in day-to-day use, such as digital monitoring with KSB Guard, the PumpDrive variable speed system, or the new EtaLine Pro pump with digital control technology. 

What are the aims of DrinkTank?

Almost everyone in the industry would agree that the beverage industry has to become more digitalised. However, many companies still hesitate to actually take this step as the hurdles often seem insurmountable. Finances and resources have to be invested in a targeted and sustainable manner. DrinkTank was founded to identify the challenges and problems of starting off with digitalisation and to develop practical solutions – covering all phases of the production process where possible. DrinkTank is divided into two segments:

1. The task force
   All DrinkTank participants meet regularly three times a year to exchange specific information, have workshops and jointly generate new impulses and project ideas.
2. The real laboratory
   To be able to test ideas and concepts in a real-life setting without any drawbacks, a small 10 hl testing brewery is currently being built.

The testing brewery demonstrates how it can work

On the Buschhütten campus, a mini brewery with a capacity of 10 hl will be completed by early 2024. It serves to demonstrate and test new processes and technologies. This is where participating companies can "play around" and show the added value of digital transformation in production. The brewery will further be used to research applications of artificial intelligence and turn them into a tangible experience. Real test products will be produced under market conditions with a view to efficiency and sustainability. The testing brewery will shortly be put to the test in two different study projects:

1. How can tanks be cleaned more efficiently?

The starting situation
At present, the cleaning duration of product tanks is based on experience and the employees’ visual checks. After cleaning, an analysis is conducted to prevent any cleaning agent residues from mixing with the product. Neither visual checks with cameras nor in-line clinical/physical measurements are in place. Also, the cleaning lye is not analysed to determine the degree of cleanliness. At the same time, the cleaning process uses a vast amount of resources and power. Question: How can the cleaning process be made more efficient using intelligent sensors?

The procedure
First of all, the project team will draw up a concept defining what data are relevant to the cleaning process, where the measurement points are located, and what sensors are to be used or developed for this purpose. Then, the process will be tried out cleaning a tank of the testing brewery and comparing it to the cleaning of a tank in the conventional way. Once the results have been successfully validated, their transferability to large plants will be worked on.

The expected outcome
One of the objectives of optimised tank cleaning is a higher availability of the tank. At the same time, less energy, water and cleaning agent are to be used for cleaning, and the tank cleaning process is to be documented in a traceable way.

2. How can energy use be monitored more accurately?

The starting situation
For an optimum process analysis and optimisation, it is important to know where exactly energy is required and consumed, and how much of it. The problem is: Consumption is usually measured "globally" over the entire process with "locally" measured values being the exception.

The procedure
The project team uses a structured procedure for energy monitoring. This starts with process modelling to comprehend the energy consumption. Next, existing measured values will be used and new measurement points defined. Accurate forecasts enable planning for resource allocation and future energy consumption trends. The effects of different measures are analysed using interaction modelling. And finally, process control optimises energy consumption, which results in savings. 

The expected outcome
By using energy monitoring and intelligent control of energy flows, the partners expect that the energy consumption of the brewing process can be lowered. Potentials can specifically be traced back to the following:

• Methodologically identifying relevant consumers and their interaction
• Using data as a prognosis tool
• Applying a detailed planning algorithm

Summary

To promote digital transformation in the beverage industry, about a dozen companies and institutions have come together under the lead of Siegen university to found the "DrinkTank" network. Apart from having regular meetings, the network runs a small testing brewery that will help try out and develop ideas, solutions and concepts in real-life conditions.