Liquids & Drinks · Beer & Brewing

Pasteurizer Energy & Control

Tighten pasteurization units to ±3 PU while cutting steam consumption by 18% per hectoliter.

−18%

Steam Consumption

Per-hectoliter steam use reduced from 2.2 average to 1.8 kg/hL through tighter holding temp control

±3.1 PU

PU Consistency

PU variance tightened from ±8 to ±3.1, ensuring microbiological safety margin without over-processing

−$340K/yr

Product Loss Prevention

Elimination of PU deviation-triggered holds and diversions on two pasteurizer lines

How Allie Works Here

From signal to action in real time.

Energy OptimizationProcess ControlQuality ControlPredictive Maintenance

The Process Control agent computes real-time Pasteurization Units from holding tube temperature and product flow rate, comparing against the certified process schedule stored in the MES. When PU trending indicates risk of under-processing, the agent adjusts the steam valve setpoint via Siemens PCS 7 OPC-UA interface to tighten holding temperature without stopping flow. The Energy Optimization agent monitors steam consumption per hectoliter across the shift and recommends steam header pressure reductions during off-peak production windows, reducing energy cost without impacting microbiological compliance. The Predictive Maintenance agent tracks plate gasket leak signatures and heat exchanger fouling rate (ΔP-vs-flow trajectory), pre-scheduling plate inspections via the Maintenance agent, with the relevant Alfa Laval service procedure and prior gasket-replacement history attached to the work order.

Machines & Connectivity

OT-connected, protocol-native.

Alfa Laval Plate Pasteurizer

Alfa Laval

Modbus TCP

Flash pasteurization at 72°C for 15 seconds; multiple holding tube temperature zones

Endress+Hauser Promag P 300 Flow Meter

Endress+Hauser

Modbus TCP

Volumetric flow measurement for throughput and energy-per-hectoliter calculation

Siemens PCS 7 DCS

Siemens

OPC-UA

Distributed Control System managing all temperature, flow, and CIP permissives for the pasteurizer block

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Holding Tube Temperature	`PAST01.HOLD.TMP`	°C	70–76	72–73	Tighter
Steam Consumption per hL	`PAST01.STM.HL`	kg/hL	1.8–2.6	1.6–1.9	Lower
Flow Rate	`PAST01.FLOW.HL`	hL/hr	280–340	320–340	Higher
Pasteurization Units Delivered	`PAST01.PU.CALC`	PU	12–28	16–22	Tighter

Holding Tube TemperatureTighter

PAST01.HOLD.TMP

Baseline: 70–76 °C→ 72–73 °C

Steam Consumption per hLLower

PAST01.STM.HL

Baseline: 1.8–2.6 kg/hL→ 1.6–1.9 kg/hL

Flow RateHigher

PAST01.FLOW.HL

Baseline: 280–340 hL/hr→ 320–340 hL/hr

Pasteurization Units DeliveredTighter

PAST01.PU.CALC

Baseline: 12–28 PU→ 16–22 PU

In the Field

"a Latin American brewer operating beer and soft drink lines across multiple plants, pasteurization improvements rolled into a Siemens-referenced reference architecture"

Deployed at a Latin American brewer operating beer and soft drink lines across multiple plants, pasteurization improvements rolled into a Siemens-referenced reference architecture. The results above reflect production data from the 60–90 day period following full deployment.

−18%steam consumption

±3.1 PUpu consistency

−$340K/yrproduct loss prevention

Next Step

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