Baltika Breweries

The cost of packaging materials has been lowered by 1.8% annually

Baltika Breweries

Baltika Breweries automates production process with Manufacturing Execution Systems, providing significant increase in data accuracy and streamlined reporting practices.

Goals

  • The brewery required a modular automation software solution that would enable operations management to scale the system to meet future production requirements
  • Reduce costs through improved equipment performance, lowered material losses, reduced production costs, and better supply chain processes from distributor warehouses

Challenges

  • Ensuring that a new automation software solution could effectively integrate with existing hardware and software while increasing overall equipment performance
  • Because accurately monitoring supplies of source ingredients is critical to maintaining adequate levels of brewing production, there was concern that an appropriate software solution may not be available
  • With increasing global competition, reducing the facility’s production cost was a top priority for any new software implementation

Results

  • The reduction of 8% in energy usage during the manufacturing process has enabled Baltika to lower its overall operating costs
  • A 5% reduction in steam consumption during the beer manufacturing process has been achieved
  • The cost of packaging materials has been lowered by 1.8% annually
  • Baltika can now accurately determine production losses per batch and has achieved a reduction of 0.56% in extract loss

"The comprehensive AVEVA MES solution has provided a significant increase in the accuracy of our process control system enabling our operators to monitor the manufacturing lines in real time and more quickly react to anomalies that might occur. " - Yuriy Chentyrev, Director of Operations

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