In the course of modernizing its bottling plant, Carl Jung from Rüdesheim am Rhein had to look for new ways to make the production process for its non-alcoholic wines more efficient. The company relied on Corosys, which supplied a system for recording and visualizing the process data in addition to its systems and machines - as a kind of system integrator.

Under the 'SmartMachine' label, forecasting models on the technical condition of the systems are possible, for example for predictive maintenance, but also for detailed and reliable statements on process progress and product quality. Corosys uses routers and IIoT communication gateways from Wachendorff 's 'Ewon' series as important components in the overall technical concept. Important key performance indicators are visualized on site using the KPI dashboard from Visualys.

What does the modernization concept look like in detail?

The upcoming modernization of the bottling plant presented Corosys with the opportunity to implement an automatic wine filter system including a CIP system. Cleaning in Place' is a process for cleaning production systems and pipelines. The system is cleaned in a circular or continuous process without prior dismantling.

In particular, the automatic cleaning, sterilization and validation of the filter system saves time in filling preparation and ensures a consistently good cleaning result. By monitoring the pressure losses, blocked filter elements can be detected at an early stage and regenerated before a complete cleaning is necessary.

The specific challenge with the CIP system was to install it in a very confined space. Lye and acid are automatically dosed from IBC containers (intermediate bulk containers) set up in the chemical warehouse until the desired concentration is reached. This increases safety when handling hazardous substances. There are various automatic programs for the cleaning process so that the individual systems can be cleaned independently of each other. In addition, an automatic, time-controlled start preparation for the start of filling at the start of the week has been implemented, for example after a long period of downtime over the weekend.

SmartMachine as the linchpin

Corosys operates retrofits but also builds completely new systems. At Jung, the 'Ewon' router communicates with a Siemens PLC.

© Wachendorff

Due to the global orientation and the high export share of Carl Jung products in particular, the requirements in the area of product safety and traceability are very demanding. This is where Corosys provides valuable support with the 'SmartMachine' interface: The system control is connected to the 'Corosys Customer Database' via an encrypted VPN connection, where all process and machine data is stored in a redundant database.

In terms of connectivity, the company relies on the 'Ewon Flexy 205' series VPN routers from Wachendorff Prozesstechnik. This is because classic remote access by service technicians to the customer's systems via the Internet, to control systems from a wide range of manufacturers, is mandatory. Accesses are logged precisely and alarms are also sent by e-mail or SMS.
Should a fault occur in the system that the on-site personnel cannot rectify independently, the 'SmartMachine' interface comes into play to support commissioning and maintenance and ensure predictive maintenance.

The prerequisite for these points is the central recording and processing of machine and system data. For this purpose, the 'Ewon Flexy 205' remote maintenance router collects and stores machine data directly from the PLC and transmits it in encrypted form via secure data interfaces (REST API). Within the 'Talk2M' connectivity cloud, the router offers an interface for historical data (DataMailbox) and one for actual data (M2Web API). This data is then collected and analyzed centrally at Corosys.

A service contract is concluded with the respective system operator to specify in detail which data is to be recorded, who has access to it and for what purpose. A distinction is made between production, service and machine data. Corresponding roles, linked to access rights, are set up.
In this way, Corosys can offer service and support for the systems supplied and also provide the system operator with meaningful overviews of the production data and status of their machine. Proof of cleaning cycles and other food hygiene standards can also be generated automatically via this interface.

For example, the 'SmartMachine' server monitors the fully automatic night-time machine cleaning at Carl Jung and sends a daily cleaning report with all the necessary information to the production manager. The same applies to the production and monitoring of pressure differences on the wine filter system. The plant operator can connect to the user interface of the 'SmartSupport' software via the Internet to display predefined values, status and trend curves.

The software monitors the process data almost in real time. In the event of a limit value violation, the system notifies production management and the support team by email and text message via the alarm management system that has been set up.