50% Reduction in Energy Consumption at the Carlsberg Brewery in Brzesko

Food industry

At Control-Service, we actively support the industrial sector in pursuing greater energy efficiency and implementing sustainable development strategies. A prime example of this commitment is our collaboration with the Carlsberg Group — at the Okocim brewery in Brzesko, we carried out a modernization of the hydrofor and ventilation systems. By implementing advanced Danfoss frequency converters — the VLT® AQUA Drive FC 202 and VLT® HVAC Drive FC 102 — we optimized system performance and reduced electricity consumption by as much as 50%.

GOALS:

Reliable water distribution.
Proper air exchange in rooms.
Carbon dioxide evacuation.
Dew point control.
Historical data collection and advanced reporting.
Regular inspections and ensured production continuity.

CHALLENGES:

Irregular pump shutdowns and startups.
Pressure exceeding actual demand.
Integration of the overall production process control system with the production hall ventilation.
Use of components compatible with other systems.

SOLUTIONS:

Two VLT® AQUA Drive FC 202 frequency converters, three pumps, and a 55 kW soft starter.
Multi-level protection system.
Sixteen VLT® HVAC Drive FC 102 converters ranging from 4 to 18.5 kW.
Siemens S7 315-2DP controller, SCADA system, WinCC.
Internal and external temperature and humidity sensors.
Two zones: NW1 – for the beer bottling area, and NW2 – for the transport area.

BENEFITS:

Approximately 17% higher efficiency.
50% reduction in electricity consumption.
ROI ➞ 7 months.
Capability to generate advanced report.
Testing of individual equipment groups.
Access to key process parameters and the ability to retrieve them at any time.
Optimization of spare parts inventory.
Integration with the production system.

Hydrophore system

Before the modernization, the water supply system was characterized by irregular pump operation and unstable pressure, which led to excessive energy consumption and an increased risk of failure. We designed and implemented a system consisting of two VLT® AQUA Drive FC 202 frequency converters, three 55 kW pumps, and a soft starter. This solution allowed for:

Achieving stable water pressure adjusted to current demand.
Reducing electricity consumption by approximately 50% compared to the previous system.
Fast return on investment – the additional converter paid for itself within seven months.
Improved reliability thanks to redundancy – in case of failure of one converter, the other automatically takes over its function.

HVAC system

In the area of ventilation and air conditioning, the key objectives were to ensure proper air exchange, dew point control, and carbon dioxide removal. We applied VLT® HVAC Drive FC 102 frequency converters, which enabled:

Intelligent control of fans and valves thanks to the built-in Smart Logic Controller.
System operation aligned with the production cycle – during periods of lower demand, energy consumption dropped by up to 80%.
Historical data collection and analysis, which allowed for optimization of beer production and storage conditions.

Results and Further Actions

Thanks to the modernization, the Okocim Brewery achieved significant energy savings and improved the reliability of its systems. The project’s success inspired other Carlsberg Group facilities to implement similar solutions.

Our cooperation with Carlsberg Polska has continued uninterrupted since the project’s completion. We provide ongoing service support and predictive maintenance, ensuring long-term efficiency and safety of production processes.

To date, we have implemented 4 hydrophore installations and 9 HVAC control systems in Carlsberg Group breweries, using a total of 203 Danfoss frequency converters.

For a more detailed insight into the project, we invite you to watch the video:

realizacje

GOALS:

Reliable water distribution.

Proper air exchange in rooms.

Carbon dioxide evacuation.

Dew point control.

Historical data collection and advanced reporting.

Regular inspections and ensured production continuity.

CHALLENGES:

Irregular pump shutdowns and startups.

Pressure exceeding actual demand.

Integration of the overall production process control system with the production hall ventilation.

Use of components compatible with other systems.

SOLUTIONS:

Two VLT® AQUA Drive FC 202 frequency converters, three pumps, and a 55 kW soft starter.

Multi-level protection system.

Sixteen VLT® HVAC Drive FC 102 converters ranging from 4 to 18.5 kW.

Siemens S7 315-2DP controller, SCADA system, WinCC.

Internal and external temperature and humidity sensors.

Two zones: NW1 – for the beer bottling area, and NW2 – for the transport area.

BENEFITS:

Approximately 17% higher efficiency.

50% reduction in electricity consumption.

ROI ➞ 7 months.

Capability to generate advanced report.

Testing of individual equipment groups.

Access to key process parameters and the ability to retrieve them at any time.

Optimization of spare parts inventory.

Integration with the production system.

Hydrophore system

HVAC system

Results and Further Actions

Control system for resin condensation reactors with a recipe module and a production process simulator

Modernization of the pumping station part 2 – Implementation of new a control system (Simatic S7-1500) and visualization in the Wonderware InTouch

Visualization system for media and auxiliary installations

Media visualization system and auxiliary installations operation