Asia Pacific Breweries replaces obsolete I/O modules with a stable, scalable system

They selected a system based on the Rockwell Automation Logix Control Platform, consisting of Allen Bradley ControlLogix® programmable automation controllers (PAC) and 1756 I/O. They communicate with the existing DCS on Modbus™. Asia Pacific Breweries decided to migrate the brewhouse control system in phases. First, the company would replace the I/O modules and migrate them to a newer system. It needed a new I/O system that was open and modular and could be scaled for future growth. Second, the brewer had an aggressive goal to migrate each remote I/O panel during one eight-hour period of scheduled downtime — a process that can normally take several days. To help ensure that the upgrade was completed in the scheduled eight-hour period, Rockwell Automation and Asia Pacific Breweries approached this project with a pilot and ran a “dress rehearsal” of the planned upgrade.

Rockwell Automation engineers developed the system design and were responsible for engineering, implementation, testing and commissioning the system. The dry run allowed engineers to fine-tune the implementation timeframe, troubleshoot potential problems and identify areas of improvement. The scheduled upgrade took only six hours. The brewer now can rely on a stable control system with an easy-to-maintain and scalable I/O system. This helps the company to meet their rapid production growth, and ensure timely delivery to their global customers. From the brewer’s perspective, the greatest measure of success was that the project was completed in one day: They did not miss any shipments, and the customers didn’t notice anything at all.