Overview
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BRAUMAT & SISTAR
BRAUMAT & SISTAR - the cross-industry control system specifically for the control and monitoring of recipe-controlled production processes such as in the food and beverage industry, as well as for all comparable batch and recipe-based production processes.
The following industries can be cited as examples:
- Beer production
- Milk processing
- Battery manufacturing
- Mixing processes
- And other comparable batch-oriented production processes
The system software is attuned to the technological requirements of such production processes and contains the following functions, among others:
- PLC-based recipe control by processing the specified product recipes
- Operator control and monitoring system with server/client architecture
- Graphics-based recipe and order management
- Automatic weighing and dosage of raw materials and inputs
- Route control of pipe and valve-related transport procedures (e.g. in tank farms)
- Messaging and logging
- Test and diagnostics
- Engineering and configuration tools
BRAUMAT & SISTAR Lean
In addition to the BRAUMAT & SISTAR standard system (Standard Edition), the Lean Edition of BRAUMAT & SISTAR is also available.
This is especially aimed at the needs of smaller plants (e.g. microbreweries and craft breweries) or encapsulated plant units (e.g. thermal treatment such as 'short-time heating') and provides an easy and cost-effective entry-level system.
Benefits
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Based on the Siemens "Totally Integrated Automation (TIA)" automation concept, BRAUMAT & SISTAR brings the following advantages and benefits for the reliable operation of the plant and for efficient and flexible engineering:
- Based on the robust and proven industry standard with the S7-1500 controller family
- Modular control system with powerful, distributed server-client architecture
- Flexible and simple integration of field devices and drives on the basis of PROFINET and PROFIBUS
- Seamlessly scalable, from the smallest unit to a large plant network
- Maximum availability through optional server and PLC redundancy
- Efficient, plant-wide engineering
- Simple and quick system expansions and optimization during operation
Furthermore, automation with BRAUMAT & SISTAR allows the following objectives to be attained:
- Increased availability and safety of the production process due to robustness, redundancy, and access protection
- Transparency and traceability in production, transport and storage facilities
- Assuring the quality of the product through the reproducibility of proven recipes
- Product innovations due to the development of new recipes
- Increased efficiency and productivity through the optimized use of resources and equipment
- Standardization by configuring in accordance with ISA-88 (IEC 61512-1)
The system is structured in such a way that it can be optimally adapted to the respective plant with comparatively little configuration effort. The configuring and operation of the system can be handled by technologists or operating technicians.
Design
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A BRAUMAT & SISTAR system consists of the following system components:
Visualization and control level
At the control level, BRAUMAT & SISTAR, as a PC-based control system in server/client architecture, provides functions for operation and visualization as well as for data archiving.
B&S servers are used in individual or redundant configurations as a central element for connecting to the lower-level PLC control technology. As a rule, one B&S server system is used per plant area (in keeping with ISA-88).
Clients connect to the IOS server systems and are used for central or local operation and visualization. There are two client variants:
- Multi Area Client – for cross-area connection and visualization
- Single Area Client – for connection and visualization within the same area
Control level
Programmable logic controllers (PLCs) are used for the process control level, consisting of SIMATIC S7-1500 programmable controllers with the associated technological program modules. They handle closed-loop and open-loop control tasks, monitoring of process operations, measured value acquisition, and the processing and control of product transfers. These tasks are processed largely autonomously by the control system, even if there are interruptions in communication with the connected servers.
Configuration & Engineering
Engineering of the B&S system is performed in the integrated configuration tools; supplementary configuration and programming of the S7-PLC is takes place directly in STEP 7.
BRAUMAT & SISTAR provides the plant planner and the operating personnel with a full range of standardized configuration and engineering tools, which can be used to structure the system in accordance with the ISA-88 standard to ensure its general transparency.
BRAUMAT & SISTAR Lean
The Lean edition of BRAUMAT & SISTAR provides a simple and cost-effective entry level system, especially for the requirements of smaller plants (e.g. microbreweries and craft breweries) or encapsulated plant units (e.g. thermal treatment such as "short-time heating"). This is provided by the needs-oriented range of functions and the scalable licensing of the required quantity structure.
A Lean system always consists of a PLC in combination with a single PC station, where in addition to local visualization the engineering takes place. The plant quantity structure is licensed by step-by-step enabling of the needed units (definition as per ISA-88) up to a maximum quantity structure of 40 units. Additional clients for distributed operation can also be added.
Basically, all of the functions of a BRAUMAT & SISTAR "Standard Edition" are available to a Lean system. This also includes, above all, the range of functions of the replay mode.
However, the optional server redundancy expansion and the Route Control System (RCS) are not possible in a Lean system:
The switchover from a BRAUMAT & SISTAR Lean system to the "Standard Edition" is easily possible. The existing engineering project can be seamlessly migrated and can continue to be used.
The following license packages are available for the Lean edition:
- Lean basic package:
Forms the basis of a Lean system, contains the components B&S single server, PLC and B&S Engineering, and permits the configuration of up to 4 units
- Lean PowerPack:
Expands the basic Lean system by an additional 12 units. The PowerPack can be purchased and installed up to 3 times per Lean basic system. This will enable the gradual expansion to up to 40 units (4, 16, 28, 40 units).
- Lean conversion packages:
Enable migration from a BRAUMAT & SISTAR Lean system to a BRAUMAT & SISTAR Standard system. A corresponding conversion package is available for each B&S Lean PowerPack level (4, 16, 28, 40 units).
Function
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The following technological modules are available to the user:
Order system
The following functions are available to the operator in the order system:
- Simple and convenient creation and processing of production orders as batches
- Specification of additional production parameters with automatic scaling of the recipes to the specified batch size
- Clear display of order status and progress
- Overview of completed orders
Graphical recipe system
The graphical recipe system provides the following functions for creating, managing and parameterizing recipes:
- The processing steps of the production, along with their sequences, alternative routes and synchronization points, are defined in the recipe procedures by grouping together various basic operations.
- The component list contains descriptions of the raw material components that are needed for the production of a specific recipe.
- The production parameters for the recipe (e.g. time, temperature, pressure, etc.) are described in the basic recipe. These parameters can be entered dynamically (e.g. depending on the order, the recipe type, or via manual entry).
- Comprehensive recipe management and creation systems are integrated with a user-friendly interface. The recipe system corresponds to the specifications of the international standard ISA-S88 or IEC 61512-1. The operation and visualization are done graphically and in list format.
Replay Mode
Replay Mode enables the subsequent playback of recorded process data directly in the process pictures and picture elements. For this purpose, during Replay Mode the process pictures are provided with the recorded historical process data instead of online process data.
Operation is the same as with a video recorder: start time, replay speed, and start/pause can be controlled by the user.
Visualization of Replay Mode can take place at the same time as visualization of the real-time mode, e.g. on a second monitor, so that the current production status is also always kept in view.
Replay Mode thus supports the operator, service technician, or commissioning engineer in the following:
- Diagnosis of the cause of error states
- Tracking of production processes (e.g. for subsequent process sequence analysis when unexpected product quality issues arise)
- Optimization of production processes
- Training of new operating personnel
Dosage management
The weighing and dosage system offers the following properties:
- Integrated in the recipe system
- Fully automatic single and multi-component weighing processes
- Reproducible accuracy
- Uniform operation of different weighing systems (SIWAREX, metered scales, tilting scales, etc.)
- Free assignment of components to storage locations (e.g. silos) and scales
- Setting of weighing parameters (e.g. coarse and fine flow, tolerances, calibration, etc.)
- Dosing via volumetric and flow meters
Route Control System (optional)
Pipe-based production plants typically have a large number of alternative production and transport routes. Cleaning programs and cleaning agents (CIP – Cleaning in Place) must also be safely controlled in terms of production sequence and product flow.
The optional route control system allows the technological configuration of the production and CIP routes, clear diagnostics for servicing and operating, and documentation of all of the routes by means of cross-reference lists.
The route control provides the following functions and benefits:
- Tool for engineering complex product routes
- Runtime system for controlling product or CIP routes
- Diagnostic and messaging tool for product or CIP routes
- Illustration of complex product or CIP routes of large plants
- Effective configuration by division into partial routes
- Uniform and transparent configuration of the routes
Note: The Route Control System functionality is only supported for the following PLC types:
- CPU 1517-3 PN/DP (FW2.6 or higher)
- CPU 1517F-3 PN/DP (FW2.6 or higher)
- CPU 1518-4 PN/DP (FW2.6 or higher)
- CPU 1518F-4 PN/DP (FW2.6 or higher)
- CPU 1518HF-4 PN/DP (FW2.6 or higher)
More information
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More information is available on the Internet at:
- General information: Braumat or Sistar
- Sales release BRAUMAT & SISTAR V8.2 in the SiePortal – entry ID: 109955789, link
- Manual BRAUMAT & SISTAR V8.2 in the SiePortal - entry ID: 109973392, link