50% Reduction in Energy Consumption at the Carlsberg Brewery in Brzesko
We support industry in improving energy efficiency and implementing sustainable development strategies. A good example is our cooperation with the Carlsberg Group — at the Okocim Brewery in Brzesko, we carried out modernization of hydrophore and ventilation systems. By implementing VLT® AQUA Drive FC 202 and VLT® HVAC Drive FC 102 Danfoss variable frequency drives, we optimized system performance and reduced electricity consumption by up to 50%.
Goals
- Reliable water distribution
- Proper air exchange rates in rooms
- Carbon dioxide extraction
- Dew point control
- Collection of historical data and creation of advanced reports
- Regular inspections and ensuring production continuity
Challenges
- Irregular switching of pumps on and off
- Pressure exceeding system demand
- Integration of production process control system with hall ventilation
- Selection of components compatible with other systems
Solutions
- 2 VLT® AQUA Drive FC 202 frequency converters, 3 pumps and a 55 kW soft starter
- Multi-level protection systems
- 16 VLT® HVAC Drive FC 102 frequency converters ranging from 4 to 18.5 kW
- Siemens S7 315-2DP controller, SCADA and WinCC systems
- Indoor and outdoor temperature and humidity sensors
- 2 zones: NW1 for the beer bottling area and NW2 for the transport area
Benefits
- Higher efficiency by approx. 17%
- Electricity consumption reduced by 50%
- ROI: 7 months
- Ability to generate advanced reports
- Testing of individual equipment groups
- Access to key process parameters with full historical traceability
- Spare parts inventory optimization
- Integration with production systems
Hydrophore system
Before the modernization, the water supply system operated irregularly and pressure levels were unstable. This led to excessive energy consumption and increased the risk of failures. 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 enabled:
- stabilization of water pressure according to current demand
- reduction of electricity consumption by approx. 50% compared to the previous system
- fast return on investment — the additional frequency converter paid back within 7 months
- increased reliability through redundancy — in case of failure of one converter, the second automatically takes over its function
HVAC system
In the area of ventilation and air conditioning, the key objective was to ensure proper air exchange, dew point control, and carbon dioxide removal. We implemented VLT® HVAC Drive FC 102 frequency converters, which enabled:
- intelligent control of fans and valves using the Smart Logic Controller
- adaptation of system operation to the production cycle
- energy savings of up to 80% during periods of lower demand
- collection and analysis of historical data
- optimization of production and beer storage conditions
Results and further actions
Thanks to the modernization, the Okocim Brewery achieved significant energy savings and improved system reliability. The success of the project became an inspiration for other facilities within the Carlsberg Group, which decided to implement similar solutions.
Our cooperation with Carlsberg Polska has continued since the completion of the project. We provide ongoing service support and predictive maintenance of equipment, ensuring long-term efficiency and safety of production processes.
In total, across Carlsberg Group breweries, we implemented 4 hydrophore systems and 9 HVAC control systems, utilizing 203 Danfoss frequency converters.
