Modern control technology for sustainable malt production.
Bamberger Malthouse GmbH has everything under control: A new process control system now ensures transparency from grain receipt through to the sale of malt. Thanks to a well-thought-out modernization plan, the company is able to reduce costs while significantly increasing efficiency and quality. This is a key component of the Malthouse’s modern energy management system, with a clear focus on sustainable production.
From the old system to the new concept
Even during the initial assessment, it became clear that the outdated control technology made it difficult to use resources efficiently. As a result, it was not possible to communicate or forward data to the operations management level.
In contrast, our client had the following requirements: batch-oriented production processes that could be tracked at any time , as well as the optimization of energy consumption. All data was to be available at any time in a real-time system, with operational data automatically recorded, linked to production data, and logged.
Working closely with the customer, we implemented a comprehensive process control concept that encompasses not only the main systems but also all auxiliary systems. Thanks to the modernization of the entire control infrastructure, we provide the existing “Agrar21” management system with production data to ensure key quality assurance and documentation functions.
Automation concept
Efficient production and automated recipe management in a transparent process.
New hardware concept
The system uses modern Simatic S7 controllers in conjunction with standard PCs or industrial PCs. All devices are connected via Profinet and are used for centralized process control. This provides a cost-effective way to communicate over Ethernet.
Standardization as the key
The WinCC-based process control system is designed as a redundant client-server solution. The most important aspects here are the technological functions tailored to the specific tasks in the Malthouse: standardized software modules with configurable logic that are ideally suited for recipe-driven batch processes.
Real-Time transparency
Thanks to the technological process control system—which uses step sequences, procedures, and parameters—the customer can exchange information with the management system in real time at any time. All raw materials and formulas used are recorded centrally in a database.
”The new process control system provides the Bamberg Malthouse with crucial insights into malt production, ensures consistent quality, and serves as the central information hub.
Thomas BuxGeschäftsführer, planemos GmbH
