Electricity + Control September 2018

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

Nonetheless, in Austria's largest private brew- ery, brewing beer still is a craft: State-of-the-art technology only makes it easier. "The new system helps us compensate natural variations in the raw materials and maintain a consistently high quality," says Christian Pöpperl, master brewer in chief at Stiegl, who was responsible for the transition to the new automation system, explaining the advan- tages of the digitised brewhouse. After taking this step in technological evolution, the master brewers have noticed that they suddenly have time for their true passion again: coming up with new recipes. Traditionally, only hops, malt, yeast, and water go into the kettles of German breweries, but even a truly traditional beverage has to be marketed ― and that is where the beer label makes its grand en- trance. Simple paper is transformed into a unique branding tool, intending to influence in no small part the consumer’s purchasing decision. But looks are not everything – such a label should be able to withstand changing tempera- tures, condensation, storage periods, and bottle washing machines. Expectations are therefore high, as are the requirements for producers along the value chain. Refined, printed, and glued The beer label first sees the light of day in the pa- per mill. In order to refine the simple paper after the initial manufacturing steps, it is usually metal- lised and embossed. The resulting gloss heightens the sense of anticipation for a cool and refreshing beer. Such tasks rely heavily on state-of-the-art drive technology. The next stage of the process takes place at the printers: the paper must have proper fibre run- nability for optimal ink application. This can often be a real challenge, as labels are asymmetrical in structure and the surfaces of their different sides have varying characteristics. The paper has to lie perfectly flat so that nothing interferes with print- ing. During subsequent cutting and punching, the labels need to be prevented from sticking to each Visual appearance is crucial, and quality pays for itself

other in blocks. In addition, the paper should be ‘punchable,’ allowing the cutting blades to glide smoothly through many plies. Printed, refined, and cut, the labels go to the bottling company, usually one of many small brew- eries. This is where they pass through the labelling machine. At a speed of up to 60 000 bottles per hour, the labels have to be applied cleanly and in precisely the right position on the bottles. In the case of cold filling, the bottles also ‘sweat’ so the glue must adhere well to the back of the label. The bottles are then usually rinsed and packaged in crates or six-packs. Integrated control technology is needed to prevent damage, blistering, or wrin- kling during this process. Conclusion When the beer bottle is placed on the store shelf, the label can make its grand appearance – regard- less of how short-lived. But the label’s lifecycle is not over yet. Once the delicious brew has been consumed, the bottle goes back to the bottling company where the label faces its last challenge: the removal process. The glass bottles are cleaned in an alkaline solution at a temperature of 80°C. The label has to be removed from the bottle with- out losing printing ink or disintegrating. Some of the high-quality paper fibres are then processed as raw material for new paper products.

A more flexible and economical process requires the digitalisation of brewing equipment along the entire value chain.

Using the Siemens Simatic S7 technology and WinCC software, Stiegl's brewhouse in Salzburg has digitised its processes from start to finish.

Moscow, Russia, Ochakovo Brewery - June 13, 2013.

Electricity + Control

SEPTEMBER 2018

5