MES.pro in Warka Brewery Case Study

Building an integrated system for a new insurer in 6 months and with a minimum financial outlay

March 28 2023

Warka Brewery

The Warka brewery is a large mass-production brewery, controlled by Heineken. The brewery is located in Warka, an area with a rich brewing history. According to legend, in 1478, the Mazovian Prince (Bolesław V) granted Warka exclusive rights to supply beer to his court.

The current plant however was opened in 1975 by the Zakłady Piwowarskie w Warszawie (Warsaw Brewing Industries).

In 1994 the brewery was privatized and became part of Warka Breweries Ltd. In 1999 it was taken over by the Żywiec Group (Heineken). Modernization followed and by 2004, the capacity had grown to 3,500,000 hl.

Heineken has also recently invested in large-scale advertising campaigns, which has helped to grow sales of the ‘Warka’ branded beers. The Warka brewery is certainly one of the most modern, large-scale breweries in Europe.

Brewery's Business Goals

Ongoing product quality control;
Reduction of batch release time for bottling;
Reduction of costly laboratory tests;
Possibility of self-expansion and modification of the system logic by employees of the Brewery;
Resignation from paper form in quality control and transition to electronic form.

Challenges Faced by the Brewery and ProService Finteco Teams

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

Real-time processing of data collected directly from over 3,000 sensors and controllers of production lines;
Providing operators with current qualitative information, analyzes and recommendations in a graphical environment;
Intuitive application interface mapping the digital model of the plant with the possibility of independent parameterization of the model and shaping the logic of the solution by the Brewery’s analysts.

Solution Deployed

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

Real-time processing of data collected directly from over 3,000 sensors and controllers of production lines;
Providing operators with current qualitative information, analyzes and recommendations in a graphical environment;
Intuitive application interface mapping the digital model of the plant with the possibility of independent parameterization of the model and shaping the logic of the solution by the Brewery’s analysts.

What does the client say about us?

"

„The MES.pro solution deployed in Warka Brewery helps us control the quality of products on an ongoing basis. It not only processes data from thousands of sensors, but also provides information and recommendations to operators for quality management. As a consequence, the system shortened the batch release time and made it possible to resign from the 3-shift work of the quality lab”

Marek Iwański, Senior Automation Specialist at Warka Brewery.

The Project Achievements

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

Real-time processing of data collected directly from over 3,000 sensors and controllers of production lines;

Providing operators with current qualitative information, analyzes and recommendations in a graphical environment;
Intuitive application interface mapping the digital model of the plant with the possibility of independent parameterization of the model and shaping the logic of the solution by the Brewery’s analysts.

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