Why Even Small/Craft Breweries Need Automation
Consistency
Consistency is key in brewing. For small breweries, maintaining the same taste, quality, and standards across batches can be challenging. Automation ensures that each step of the brewing process is precisely controlled, minimizing human error and variability. This leads to a consistent product, which is crucial for building and maintaining customer trust and satisfaction.
Efficiency and Productivity
Automation streamlines brewing processes, reducing the time and labor required for each batch. This allows small breweries to increase production without significantly increasing costs. Automated systems can handle repetitive tasks, freeing up brewers to focus on more creative and value-added activities.
Data Collection and Analysis
Automated systems provide real-time data collection and analysis, offering valuable insights into the brewing process. Small breweries can monitor key parameters such as temperature, pressure, and flow rates, allowing for quick adjustments and improvements. This data-driven approach enhances quality control and process optimization.
Compliance and Traceability
Regulatory compliance is a critical aspect of the brewing industry. Automation helps ensure that all processes meet industry standards and regulations. It also improves traceability by maintaining detailed records of each batch, from raw materials to final product. This is essential for quality assurance and recall management.
Batch Control for Small Breweries
Different Recipes
Small breweries often pride themselves on their unique and varied beer recipes. Batch control systems allow brewers to manage and replicate these recipes accurately. With automation, brewers can easily switch between different recipes, ensuring that each one is brewed to perfection. This flexibility is particularly important for small breweries that experiment with seasonal or limited-edition brews.
Scaling Production
As small breweries grow, they need to scale their production while maintaining quality and consistency. Batch control systems enable efficient scaling by standardizing processes and minimizing variations. This ensures that each batch, regardless of size, meets the same high standards.
Inventory Management
Batch control systems integrate with inventory management, providing real-time updates on raw material usage and stock levels. This helps small breweries manage their supply chain more effectively, reducing waste and ensuring that ingredients are always available when needed.
Why Traditional Automation Can Be So Expensive
The PLC
Programmable Logic Controllers (PLCs) are commonly used in industrial automation, including brewing. However, they come with a high cost due to their complex programming requirements and the need for additional hardware like IO cards and networking modules.
Batch Control Software
Batch control software is essential for managing recipes and processes, but traditional solutions can be prohibitively expensive. These software packages often require specialized knowledge to set up and maintain, adding to the overall cost of automation.
The Small to Medium dilemma
Smaller, craft style brewers often realize the benefits of modern control technology but lack the resources to fully implement such technologies. They typically have to resort to “old style” technology such as a set of single loop controllers, semi-automatic systems and the need for frequent manual intervention. Thereby losing out on the benefits offered by the latest technology such as increased throughput, improved consistency, tightly controlled quality and, ultimately, recused production cost leaving them unable to compete with their corporate counterparts.
The Solution
Why the ControlRX is Easier
The ControlRX offers a user-friendly alternative to traditional PLCs. It uses an intuitive web-based interface and optional JSON programmability, making it accessible even to those without programming experience. The ControlRX’s software includes advanced features typically found in more expensive systems, yet it’s designed to be simple and straightforward.
Why the ControlRX is More Affordable
The ControlRX integrates multiple functionalities into a single device, eliminating the need for separate IO cards, CPU chips, and networking modules. This all-in-one approach significantly reduces hardware costs and the related design and installation costs. Moreover, the ControlRX is priced at $4,959 USD, making it a cost-effective option for small breweries.
Why the ControlRX’s Software is More Affordable
Unlike traditional batch control software that requires costly licenses and specialized training, the ControlRX’s software is included with the device. It offers powerful features like PID controllers and batch control, all accessible through a web app. This reduces both upfront costs and ongoing expenses for software maintenance and updates.
A Simple Step-by-Step for Implementing the ControlRX
- Assess Your Needs: Determine the specific automation needs of your brewery, including the number of sensors and actuators required.
- Install the ControlRX: Mount the ControlRX in your brewing area using the provided DIN rail or pole mounts.
- Connect Devices: Attach your sensors, actuators, and other devices to the ControlRX’s digital and analog terminals.
- Set Up Networking: Connect the ControlRX to your network using the Ethernet, EtherCAT, or other supported connections.
- Configure the Software: Use the web app to configure your brewing processes, set up batch control, and program the PID controllers.
- Test and Calibrate: Run initial tests to ensure everything is functioning correctly and make any necessary adjustments.
- Start Brewing: Begin automated brewing with confidence, knowing that the ControlRX is managing your processes accurately and consistently.
Conclusion
Automation is a Definitive Requirement for Breweries, Even Small Ones
Automation brings consistency, efficiency, and scalability to brewing processes. Even small breweries can benefit from the precision and reliability that automation provides.
Automation Does Not Need to Be Expensive Nor Difficult
Traditional automation solutions can be costly and complex, but the ControlRX offers an affordable and easy-to-use alternative. With integrated hardware and user-friendly software, it simplifies the automation process.
The ControlRX Might Be the Perfect Solution for You
If you’re looking for an affordable, easy, and effective way to automate your brewing process, the ControlRX is an excellent choice. Its cost-effective design, intuitive interface, and powerful features make it an ideal solution for small breweries looking to enhance their operations.
