Networked IT concept for soft drinks production

Maximised availability of the plant as a whole coupled with minimised staffing levels – that’s the result of the IT solution in use at the Vitaqua facility in Breuna, Germany, for soft-drinks production. The IT modules cover the entire production and logistics processes.

Planning work for production and dispatch orders is supported by the following IT packages:

• fine-planning system,
• line management system (LMS) for controlling the production orders, 
• process control for the syrup kitchen featuring the batch-oriented Botec F1 process control system,
• the logistics system for incoming and outgoing goods processing and for courtyard management,
• quality management system (LIMS) for monitoring the raw materials, and the batches during bottling, and the retained samples, as well as for conducting graduated microbiological monitoring.
• production data acquisition (LDS) with all evaluation and reporting tools, plus batch tracking.

The hardware used in implementing the IT infrastructure incorporates dependable components matched to the requirements of the software products involved. Redundantly structured servers and storage systems ensure high system availability. In the bottling, order-picking and process sections, a wireless LAN enables the network to communicate with handheld scanners and mobile PC systems.
The interaction of the individual IT modules covers the entire soft drinks production process, beginning with water extraction from the firm’s own wells and the entire process section, like beverage production from the various basic ingredients and aroma components. Filling and packaging have also been integrated, all the way through to the distribution logistics.
This high degree of automation is a crucial factor underpinning the maximised performance of approximately 4 million fills a day in four-shift operation 363 days a year. The plant is networked with the other facilities of the mineral water bottlers Brandenburger Urstromquelle in Baruth and Treuchtlingen, ensuring fully accessible information provision on all levels of the company.