Bespoke Automation
About Our Automation
Case Study 1 – Comprehensive Distillery Control
Vitikit collaborated with a distillery to conceptualize and implement a state-of-the-art touchscreen control system, featuring remote accessibility for process supervision and software adjustments. The system was meticulously designed to incorporate ATEX instrumentation, with motors and heaters compliant with ATEX zones, following a thorough DSEAR assessment. Additionally, the system efficiently distributes and interlocks power throughout the process, optimizing amp input during distillation.
Vitikit’s solution facilitates control and monitoring of:
- Critical process temperatures
- Safety temperatures
- ATEX vent health – ensuring continuous flow and operation
- Pot pressure
- Waterbath levels
- Heat power regulation through thyristor
- Cleaning-in-Place (CIP)
- Molasses pump operation
- Fermentation control via a chilling jacket
- Heating and blending tank functionality.
This tailored approach enhances operational efficiency and ensures precise oversight of crucial parameters in the distillation process.
Case Study 2 – Holistic Brewhouse Management
Within the realm of brewhouse control, Vitikit’s expertise shines through. In this particular case, close collaboration with the client allowed Vitikit to ingeniously optimize the use of a limited electrical supply. The approach involved strategic power interlocking to non-critical areas during kettle operation, ensuring continuous functionality in essential zones, such as the chilling system.
Vitikit’s solution empowers effective control and real-time monitoring across various facets, including:
- Efficient management of the hot water tank through a timed system for economical overnight energy consumption.
- Kettle control, incorporating an auto-boil ramp-down feature.
- Precision timers with alarms for seamless hop additions.
- Streamlined control of grain delivery, featuring automated batching of hot liquor.
- Monitoring of Fermentation Vessel (FV) timers, tracking gyle fermentation times.
- Automated ramp-up functionality on the chilling system.
- Temperature oversight, including remote monitoring, across 5 FVs and 1 mini CLT.
- Secure emptying procedures for grains.
- Implementation of Cleaning-in-Place (CIP) protocols.
- Thorough data logging of mash and fermentation temperature profiles.
Vitikit’s tailored approach to holistic brewhouse management not only enhances operational efficiency but also provides an encompassing solution for comprehensive brewing oversight.
Case Study 3 – Soft Drink Production Facility
Vitikit collaborated with a leading soft drinks company to elevate its soda range and production capacity. The focus was on integrating customized carbonation tanks, mixing tanks, and a unique “Soda” brewhouse. Additionally, Vitikit installed an exclusive touchscreen control system with remote access for seamless management.
Vitikit’s solution encompasses monitoring and control of various aspects, including:
- Rapid cooling of the “mash tun” through a chilling jacket and Heat Exchanger recirculation.
- Continuous monitoring of flow and temperature on the product side of the heat exchanger to prevent freezing.
- Temperature oversight and control across a bespoke blending skid.
- Automated “Fast Carbonation” in the Bright Beer Tank (BBT), with pressure monitoring and CO2 dosing as required.
- Monitoring and control of the cold water tank, with automated batching of cold water as needed.
- Chiller monitoring, incorporating an “eco” mode for energy efficiency.
- Intelligent interlocking of equipment to prevent excessive amp usage, such as locking pasteurizers when the brewhouse is operational.
- Automatic “Stable Package” featuring CO2 dosing at a high flow rate to maintain constant packing head pressure.
- Temperature control of Carbonation tanks.
- Remote overview for comprehensive monitoring.
Vitikit’s tailored approach to soft drink production facilitates enhanced efficiency and control throughout the entire process.
Case Study 4 – Tank Farm Management
Vitikit is well-versed in the comprehensive control of fermentation, conditioning, and storage vessels within its brewhouse control system. However, recognizing specific needs, especially for standalone systems, is crucial, particularly in the context of receiving vessels for contract packers.
Vitikit’s solution provides monitoring and control for:
- Individual tank temperature.
- Individual tank pressure.
- Valuable feedback from valves, offering proof of position.
- Chiller status, with a Modbus connection for seamless communication.
- Temperature oversight in the glycol loop.
- Instant text notifications if parameters are out of specification.
- Pump speed control, intricately linked to glycol line pressure, with the possibility of PID control.
This tailored approach ensures precise management of tank farms, offering a standalone system that meets the unique requirements of contract packers while maintaining the high standards set by Vitikit’s control solutions.
Case Study 5 – Integrated Chemical Dosing Skid
Vitikit collaborated with a beverage producer facing challenges related to bath pasteurization for Bag in Box, resulting in unpredictable shelf life in kegs. The client aimed to incorporate Velcorin into their processing line, encountering an obstacle where the Velcorin Doser had a minimum flow rate higher than the maximum flow rate of the Bag in Box or keg filler.
Vitikit devised a solution by designing and constructing a buffer system. This innovative approach allowed the Velcorin doser to operate at its normal flow rate for short intervals, with the bag in box filler and keg filler drawing from the buffer tank. Velcorin, being sensitive to temperature, presented specific challenges such as freezing at low temperatures and a limited half-life at high temperatures. The residence time in the buffer tank had to be carefully managed to avoid chemical decomposition below a useful concentration.
Vitikit’s system adeptly monitors these critical factors, enabling the seamless integration of the doser into the existing packing line. Crucially, the system records and stores data over time, allowing for easy retrieval and verification of these important parameters. This tailored approach ensures effective chemical dosing while maintaining the integrity of the product throughout the packaging process.
Case Study 6 – Pasteurisation System
Vitikit engineered a pasteurisation system specifically catering to producers of beverages prone to rapid spoilage, such as cider, soda, and No and Low alcohol beer. Recognizing the need for a solution between traditional tunnel pasteurizers, which can be overly large and expensive, and smaller-scale production volumes, Vitikit’s system offers a versatile alternative. This product is a staple in the Vitikit standard range and is often readily available from stock.
Complementing the robust, straightforward, and cost-effective hardware is a customized automation component from Vitikit. The instrumentation comprises temperature sensors, level sensors, and immersion heating elements, but it is the automation that truly elevates the VitiBath
. Key features include:
- Display and data logging of approximate accumulated PUs (Pasteurization Units).Display and data logging of approximate “post-pasteurization PUs” – PUs after removal.
- Minimization of over-pasteurization to ensure product quality.
- Remote access for convenient monitoring and control.
- Energy cost tracking per cycle for efficiency analysis.
- “In-bottle” temperature probe for calibration purposes.
- Alarm notification at the end of each cycle for prompt attention.
Vitikit’s pasteurisation system, with its blend of advanced automation and reliable hardware, provides a scalable and efficient solution for producers with substantial production volumes.