Brewing Control System Upgrade

Furnace Upgrade

Malisko Engineering, Inc (MEI) was asked to upgrade a series of Opto22 FactoryFloor OptoControl Strategies for a growing Regional Brewery.

Goals

  • Seamlessly convert thousands of lines of code containing unsupported external commands to equivalent OptoScript for Grains Handling, Milling, Brewhouse, Yeast Handling/Propagation, Fermentation, Filtering/Release, CIP, and Waste Water Treatment,
  • Update Wonderware InTouch HMI to communicate with new Opto22 SNAP-PAC Controllers,
  • Work with Brewery Engineering Staff to startup and checkout each Control Strategy and Wonderware HMI application within a limited window of scheduled downtime.

Engineering Tasks & Services

  • Reverse-engineered FactoryFloor strategies and identified equivalent OptoScript instructions to replace unsupported external commands,
  • Ran each OptoControl Strategy through the PAC Control Conversion Process and reprogrammed each strategy with equivalent OptoScript code as necessary,
  • Simulated new PAC Project Control Strategies communicating to Wonderware InTouch with the new Opto22 SNAP-PAC-S2 controller in Malisko Engineering’s offices,
  • Modified the Wonderware InTouch Tag Databases to facilitate OptoOPCServer communications via Ethernet,
  • Worked with Brewing Engineering personnel to backup all pertinent live data (Set Points, Recipe Values, etc.) before switching their legacy SNAP-LCM4s over to the SNAP-PAC-S2 controllers,
  • Downloaded the converted PAC Control Strategies to new SNAP-PAC-S2 controllers and uploaded previously-saved data values for a seamless transition to the new controllers.
Hops

Project Successes

  • Successfully converted and started up the Control Strategies for all Brewing Process Areas in less than one year,
  • Minimized process downtime by working closely with Brewing Engineering Staff to execute startup and checkout during small windows of opportunity,
  • Provided post-startup support as necessary,
  • Utilized Opto22’s technical support through Malisko Engineering’s involvement in the OptoPartner program.