Brewing Transparency and Efficiency with Real-Time Digitalization

Enhancing Process Visibility and Performance

Carlsberg India, a global leader in the brewing industry, embarked on a digital transformation journey at its Mysuru facility to modernize its Brewhouse and Process (B&P) operations. The goal was to transition from manual logbooks to a fully digital, real-time monitoring system that would enhance operational efficiency, ensure data integrity, and support continuous improvement.

The brewery faced challenges such as manual tracking of brew batches, fragmented data on quality parameters, and limited visibility into equipment performance. These issues impacted consistency, traceability, and responsiveness. To address this, Carlsberg partnered with Siemens to implement a pilot "Digitalization of Brewhouse & Process Performance Management System" as part of its Industry 4.0 roadmap.

Siemens Solution for “Digital Brewing Intelligence"

Siemens' comprehensive digital solution seamlessly integrates with Carlsberg's existing automation infrastructure. The system captures real-time data directly from the source, eliminating manual intervention and ensuring accuracy and transparency across the brewing process.

Key components of the solution include:

• WinCC V8.0 SCADA and PM Add-ons 10.4 for real-time process visualization and analytics
• Automated Brew Cards and Filtration Charts for batch-wise tracking
• Key Activity Indicator (KAI) Dashboards for performance benchmarking
• Automated email reporting to key stakeholders for enhanced shopfloor transparency
• Live dashboards for machine status, brew cycle time, and fermentation tracking

The system also supports historical data analysis, enabling brewers and management to identify trends, optimize processes, and respond proactively to deviations.

Real-Time Insights and Tangible Benefits

The digital platform provides a plant-wide view of the brewing process, from raw material handling to fermentation. Operators and managers can monitor:

• Live brew tracking with cycle time and batch status
• Fermentation progress across all unitanks with deviation alerts
• Machine performance including ON/OFF status, idle time, and breakdowns
• Shift-wise operator performance and maintenance schedules
• Reduction in beer loss and improved quality control
• Golden batch prediction for consistent product quality
• Customized reports for daily, weekly, and monthly production metrics
• Remote access for SMEs to monitor and analyze brew quality anytime
• Improved operator ownership through intuitive dashboards
• Enhanced traceability and compliance with digital logbooks

The digitalization of Carlsberg's brewing operations has delivered measurable improvements across multiple dimensions. Operators now have access to live dashboards that provide real-time insights into machine status, brew progress, and fermentation conditions. This has enabled faster response times, reduced downtime, and improved ownership among shop floor personnel.

The system has also contributed to tangible resource savings. Steam consumption has been reduced by 0.2 KWH per hectoliter, while power savings have reached 200 units per month. These efficiencies have supported Carlsberg's sustainability goals and optimized energy utilization across the plant.

With the ability to track each brew in real time and analyze historical data, Carlsberg has introduced the concept of a “golden batch”—a benchmark for quality that can be replicated in future production cycles. The digital platform also facilitates lean manufacturing by maintaining historical data for up to one year, enabling brewers to investigate customer complaints and continuously improve processes.

Holistic approach from the field to glass with Siemens Xcelerator

Partnering with Siemens has been a game-changer for Carlsberg India. Their domain expertise and advanced easy to adapt solutions have enabled the seamless integration of brewing and filtration processes, automated data collection, and enhanced real-time monitoring. As a result, significant improvements in operational efficiency, data accuracy, and resource utilization have been achieved. Siemens' solutions have empowered Carlsberg India to set new standards in the brewing industry, ensuring consistent quality and optimal performance.

Alokesh Biswas, Head Manufacturing Operations, Carlsberg India

The increasing demands for healthy, sustainable products and their sustainable production require a holistic approach. Digitization enables manufacturers to prove at all times, from the field to the table, that they comply with regulations and ensure the best possible quality of beers. To do this, they need to become a Digital Enterprise, which is possible with Siemens Xcelerator at speed and scale.

Siemens Xcelerator is an open digital business platform that serves as a catalyst for accelerating digitalization journeys. It makes it easier than ever before for companies to navigate digital and sustainable transformation, providing step-by-step support to undergo digital & sustainable transformation with minimal resources and tangible impact. By combining the real and the digital worlds across operational and information technology, Siemens empowers businesses to boost productivity, competitiveness, and scale up innovations.

Learn more: Siemens India