Case study: automation of production with MES.pro in the Warka brewery

Warka Brewery

The brewery in Warka is, at least compared to most of the Żywiec Group's breweries, very young. It was founded in 1975, although brewing traditions in the region date back to the 15th century. This is also evidenced by the etymology of the name of the city and the flagship brand of the local brewery — warka, in the professional beer dictionary is a unit of measure denoting the portion of beer obtained during one brewing. So Warka has the most beer name of all brands. Beers from the Brewery in Warka quickly gained loyal fans. The most famous of them — the aforementioned Warka — is a classic lager, which owes its aroma to carefully cared for hops, the craftsmanship of hoppers and the passion of brewers.

Business objectives of the Brewery

Ongoing inspection of product quality
Reduction of batch release time
Reduction of costly laboratory tests
Possibility of independent expansion and modification of the system logic by employees of the Brewery
Abandonment of paper form in quality control and transition to electronic form.

Challenges faced by the teams of Browar and yarrl S.A.

Development of an expert system supporting Brewery specialists in production quality management:

Real-time processing of data taken directly from more than 3,000 sensors and controllers on production lines
Providing operators with up-to-date qualitative information, analysis and recommendations in a graphical environment
Intuitive application interface reproducing the digital model of the plant with the ability to parameterize the model independently and shape the logic of the solution by Brewery analysts.

Implemented solution

The team of yarrl S.A. developed and implemented with the Warka Brewery team a dedicated application on the CasePro platform of the no-code class (application development takes place without coding). The system supports the possibility of independent expansion and modification of the initial configuration by the employees of the Brewery.

By implementing MES.pro Brewery received a solution that at any time can independently update and adjust to the current production process, the controllers and sensors installed in the production lines and the expectations of the users. The user communicates with the system through a web browser, so there is no need to install applications on user stations.

What does the client say about us?

“The implemented MES.pro solution helps us to control the quality of products on an ongoing basis. It not only processes data from thousands of sensors, but provides information and recommendations to operators for quality management. As a consequence, the system reduced the batch release time and allowed the 3-shift laboratory to be dispensed with”
— Marek Iwański, Senior Automation Specialist at Warka Brewery.