Successful realignment of Störtebeker

From the brewery to the brew manufacture

Störtebeker Braumanufaktur GmbH is a medium-sized brewery in Stralsund and a member of the association "Die Freien Brauer". In 2018, 248,000 hectoliters of beverages were bottled and sold. The company decided to digitalise the entire value chain.

Beer crates and bottles

The Initial Situation

In 2012, a phase of reorientation took place which was followed by a renaming of the Stralsund brewery into Störtebeker Braumanufaktur. Today, the Störtebeker brewers do what they do best: They brew a large number of beer varieties in top quality according to Hanseatic brewing tradition.

Challenges:

  • Expansion of the capacities of the existing site in Stralsund due to the reorientation
  • Deep integration into the system landscape, including ERP/SAP system and external systems of the customer
  • Enormous complexity resulting from filling of 25 different types of beer in two bottle sizes and containers 
  • Quick changeover between the different types of containers
  • Overview through complete mapping of the processes in the production and logistics chain

The Project

Requirement:

  • Highest possible flexibility with simultaneous automation of production and logistics processes
  • Increasing the productivity of logistics space
  • Assurance of delivery capability via an optimised logistics concept with simultaneous integration of picking, display construction and empties handling
  • Digitalisation of logistics and production processes, taking into account investments already made in the IT landscape (SAP or LIMS)
  • Integration and automation of production supply and disposal

"We considered the topic Industry 4.0 at an early stage and looked for the right partners. With this investment, we have taken another significant step in this direction and hope to be well positioned for the future."

Jürgen Nordmann
Owner Störtebeker Braumanufaktur

The Solution

HOLISTIC SOLUTION FROM THE HOUSE OF KRONES

Besides a new energy-efficient bottling line rated at 40,000 returnable glass bottles an hour from Krones, the scope of supply also included a high-bay warehouse with almost 30,000 pallet slots from System Logistics, plus networking of the entire production facility with solutions from SYSKRON and Triacos.

1. LINE DIAGNOSTICS

  • Integration of machine data of the production line and availability of the data for display and evaluation
  • Analysis of machine and line malfunctions, optimisation of plant performance

2. LINE MANAGEMENT

  • Filling line control
  • Execution of production orders in the planned production sequence
  • Active monitoring of the production progress
  • Execution of planned production orders on the filling line in the planned production sequence
  • Consideration of forthcoming orders and their product changes
  • Coding of bottles, containers and pallets
  • Transmission of replenishment orders to the WCS for production supply of required material
  • Material Management App:
    • Execution of orders for the secondary packaging area or display construction (packaging)
    • Provision of materials

3. MANUFACTURING INTELLIGENCE

  • Self-service reporting and flexible reporting for the creation of individualised reports
  • Consistent batch tracking in MES and WCS including interface to LIMS

4. ASSET MANAGEMENT 

  • Maintenance planning and maintenance management
  • Order planning and execution
  • Spare parts management and personnel planning
  • Reporting system

5. TRIACOS - SAP PARTNER

  • Implementation of SAP PP-PI and SAP MM
  • Adaptation of SAP SD and SAP LES
  • Connection to MES and WMS

6. SYSTEM LOGISTICS

  • Warehouse management and material flow system (WCS)
Picture of a man and beer crates
Beer line
Beer bottle at the beach

Why SYSKRON?

  • Individual solution from one source, accompanied by a comprehensive project team 
  • High competence and many years of expertise in beverage and liquid food production
  • Holistic horizontal and vertical integration
  • Deep integration into the customer's ERP system and other external systems
  • State-of-the-art technology
  • Standardised interfaces to all IT and automation systems involved

Benefits

  • Changeover on-the-fly through batch combination
  • Reduction of downtimes and changeover times
  • Complete transparency and traceability of processes
  • Fully integrated solution suite for the entire plant
  • Harmonisation of the various subsystems and interfaces
  • Increased productivity and plant efficiency
  • Stable quality
  • Optimised management of production orders
  • Optimised resource utilisation (lines, material, operating personnel)
Störtebeker company building

Customer

[Translate to English (US):] Störtebeker Logo

Störtebeker Braumanufaktur GmbH is a medium-sized brewery in Stralsund and member of the association 'Die Freien Brauer'. In 2018, 248,000 hectoliters of beverages were bottled and sold. The company decided to digitalise the entire value chain.

Company

Störtebeker Braumanufaktur

Founded

1827

Industry

Medium-sized brewery
Over 25 different varieties of beer

Location

Stralsund, Germany