Heineken Espana Leverages Data for Improved Sustainability
Founded in 1864 in Amsterdam, Heineken is the number one brewer in Europe and the number three brewer in the world, with operations in 71 countries and over 250 brands. Sustainability has been a core operating principle for Heineken for 150 years. In 2010, the company launched an aggressive 10-year plan to reduce water usage and increase energy efficiency throughout its breweries, offices, and warehouses. When Heineken’s new brewery in Seville, Spain, started approaching its technological benchmark limits, the Seville brewery deployed the PI System as its energy and water monitoring solution to push its sustainability improvements past the technological limits.
Scaling up for sustainability
Built in 2006, Heineken España’s brewery in Seville was the company’s first greenfield brewery in Western Europe. Today, it is the largest in Europe, with a capacity of 5.2 million hectoliters. Built as a replacement for the La Cruz del Campo brewery, the new facility includes many optimization improvements and is more efficient than the old brewery. As part of its ongoing commitment to sustainability, in 2010, Heineken introduced a comprehensive 10-year sustainability plan that affected all aspects of its operations. For the Seville brewery, this meant reducing water consumption by 25% and reducing CO2 emissions by 40% based on 2008 levels.
In 2012, when the Seville brewery started approaching its technological limit, the company realized it was going to need another tool if it was going to meet targets for 2020. “We knew we were close to the technological limit,” said Consuelo Carmona Miura, Western EU electricity project lead at Heineken España. “We said ‘Okay, it’s clear that we need an energy and water monitoring and reporting system if we want to keep moving forward, because we spend 80% of our time collecting information and 20% analyzing it, when it should be the opposite. Two years ago, we started looking at energy and water monitoring solutions, but not one of them convinced me. When I saw the PI System solution, I said, ‘This is what I’m looking for.” It’s very flexible, you don’t depend on the supplier to make any modifications to the system, it’s accessible for everyone. This is why we decided to start working with the PI System.”
Structured data on tap
In 2012, Heineken España installed the PI System at the brewery. The company also decided that Asset Framework (AF) was going to be a core part of the solution. “We decided that AF was going to be the base for everything developed in the PI System,” said Carmona Miura. “We have many silos, nonintuitive tag names, a lot of equipment across the different processes. AF is a flexible asset model that allows us to organize and structure our PI System data.” In addition to organizing data and making it more user friendly, AF has given the Seville brewery increased calculation capabilities. Now, when machines are defined in AF, the primary sustainability attributes (electricity, water, and thermal energy consumption) are also defined. This means that sustainability data is available for each asset and as rollup data across divisions:
In real-time as absolute values.
In per shift, per day, and per week totals.
In weekly and monthly ratios that show the amount of water, electricity, and thermal energy consumed per hectoliter of beer produced.
Easy access for analysis
Although it’s still early in the PI System’s implementation, the Seville brewery has seen several benefits from the deployment. For one thing, the PI System has made information easier to access. “Now we spend 10% of our time collecting data and just enjoy analyzing information the rest of the time,” said Carmona Miura. “It’s totally the opposite of a few years ago.”
The PI System has also improved data quality. “In the old software, we were missing efficiency data, ratio data, historical values—we needed more flexibility in graphs,” Carmona Miura added. “Now, we can check in real-time efficiency, power, pressure, and flow and see efficiency values for last 24 hours, last week.”
With improved data and the ability to view sustainability metrics in real time, the Seville brewery can view real-time operations against both yearly sustainability targets and historical process levels and make dynamic process adjustments. As a next phase in its implementation, the Seville brewery plans to switch from fixed yearly targets to dynamically recalculating yearly targets that adjust based on real-time production and current climate conditions. In addition to improving real-time information access, the PI System has given the Seville brewery new tools for diagnosing and resolving historical issues. “We use PI DataLink and PI ProcessBook playback to analyze historical problems,” said Carmona Miura. “Using playback, you can analyze, second by second, what happened in the past. It’s helping us identify root cause of problems.” “The key for us going forward is to use data to analyze information day by day and take quick actions,” Carmona Miura added. “With the PI System, we can get quick answers for every deviation and anticipate efficiency losses. The PI System is supporting us a lot.”