Control system helps brewer increase production by 300%
The perfect beer is a harmonious blend of art and science. Automation can help by performing the measured and repetitive tasks while allowing brewers to focus on more creative, interesting and rewarding aspects. When Sadler’s Ales, a historic Black Country brewery, started to grow its business, it decided to adopt an automated process control solution to improve productivity and make the quality of its craft beers more consistent.
Sadler’s Ales located near Stourbridge, in the Black Country has been crafting beers since 1900 and is currently run by Chris Sadler, a fifth-generation brewer. Popular brews in the company’s unique beer portfolio take reference from local subjects such as the Peaky Blinder range, which has proved an instant success nationwide.
The growing demand for Sadler’s beers led to the extension of the brewhouse, which contains all the equipment needed for the brewing process. This includes a mill to crush barley grains, a hot water tank, a mash tun to obtain wort and separate it from the mash, a copper to boil the wort while adding ingredients such as hops, a heat exchanger to rapidly cool the liquid, as well as several fermentation tanks and filter systems.
Chris Sadler, managing director at Sadler’s Brewery explained: “The new facilities should help us to quadruple production. Our goal is to produce up to 1,000 barrels a week.”
The overall objective was to create a higher capacity brewing process that could be monitored and controlled more easily by the existing staff. Sadler’s contacted local specialist Clarke Controls and Distribution to help achieve the objective. On first inspection the technical team from Clarke noted the absence of any formal documentation, such as piping and instrumentation (P&I) diagrams. To address this issue, the team suggested an analysis of the plant to reverse engineer a new process control solution.
Clarke Controls and Distribution turned to its preferred process automation vendor Mitsubishi Electric to help specify the ideal automation system components. First, Clarke Controls and Distribution engineers produced an accurate P&I diagram, which allowed Mitsubishi Electric automation engineers to determine the number of inputs, outputs, analogue signals, as well as the presence of critical electric motors (mainly pumps) where variable speed control would be required.
Ian Clarke, managing director at Clarke Controls and Distribution, commented: “The absence of any information on the existing control system set-up made the reverse engineering operations particularly challenging. Therefore, the direct technical and organisational support provided by Mitsubishi Electric was key to the successful completion of the project.”
For Sadler’s to gain the greatest advantage from the new control system, Clarke Controls and Distribution and Mitsubishi Electric worked closely with the brewers to determine their needs and build a bespoke solution around these requirements. Stephen Thornton, key account manager at Mitsubishi Electric, explained: “To make sure we addressed all the challenges and requirements relevant for the brewery team, we asked the head brewer to give us a wish list on how he would like the equipment to operate. Based on this, we developed the current system.”
The various pumps, compressors and fans in the system were fitted with either Mitsubishi Electric’s
FR-E700 compact variable speed drives, or where appropriate the FR-F800 model that is specifically designed for maximum energy saving on pump and fan control applications. The various sensors and analogue components were connected to the control network using MELSEC ST Lite Remote I/O Nodes to include all the relevant process variables.
The inverters and I/O units were then connected via a CC-Link industrial fieldbus network, to a Q series Mitsubishi Electric PLC, which is designed to be ideal for building medium to large-scale control systems. The PLC is housed in a robust metal enclosure, linked to a GOT2000 Human-Machine Interface (HMI) that displays live information and alarms. As a result, brewers can monitor the equipment, as well as adjust the processes parameters live on the touch-screen operator terminal.
Thornton said: “We set the operator desk as the main focal area, locating the PLC and HMI there to centralise the control system architecture and provide easy access for control, maintenance and upgrades.”
Whilst the reverse engineering task required advanced skills and expertise to complete, the operator controls needed to be the exact opposite; hence the bespoke control system was designed for ease of use and to streamline brewing operations. The benefits from the automated control system were immediate, as production skyrocketed by 300% in less than a month, resulting in 650 new barrels available every week, corresponding to approximately 200,000 pints of beer.
Sam Pegg, production manager at Sadler’s Brewery, commented: “I have been brewing without the support of an automated process control system for many years, so initially I was a little apprehensive if I’m honest. I was, however, pleasantly surprised to learn how straightforward and easy the new solution was to use. The new control system has greatly improved my day-to-day activities from day one. Which means I can now focus on more interesting aspects, such as the development of new beers and recipes.”
Other News from Mitsubishi Electric

Latest news about Drives and motion control systems
- Danfoss and Quantum maximise uptime in the water industry
- Service helps drive and motor users to avoid unplanned downtime
- Heavy-duty AC motor drive performance at a normal-duty price point
- Moog introduces digital servo drive with Combitronic capability
- Trio Motion Technology welcomes new President as co-founders step down
- Omron introduces 1S Series AC servo drives and motors with motion safety functionality
- ABB appoints UK system integrator to support industrial drives installations
- Trio extends machine control capability with I/O expansion
- Stober helps blinds manufacturer take control of automated fabrication process
- I/O modules enable process control with the need for a separate PLC
- KEB F6 drive controllers upgrade of high-bay warehouse storage machine
- New harmony: the G5-5 harmonic recommendations demand attention
- ABB opens dedicated Drives Service Workshop serving UK market
- ABB centralises drives’ customer support in UK
- Mitsubishi Electric announces dedicated UK Drive Solutions Centres
- Soft starter reduces single phase compressor start current by over 50%
- Control Techniques launches updated PowerTools studio module and software for motion made easy
- Emerson’s new motion control portfolio delivers flexibility, scalability and reliability
- Lenze’s smart servo axis for motion control comes with IIoT functions
- Mouser Electronics signs global distribution agreement with motion control expert Trinamic
- G5/5 regulations bring important changes for VSD installations
- Controlling brushed DC motors with pulsed width modulation
- The drive to minimise power losses in machine tools
- Transicon joins Danfoss Drives’ Integrator Expert Program
- IVD supplier gets productivity boost thanks to servo system
- Nord introduces new generation of control cabinet inverters
- Servelec rebrands as ITI – Innovation Transforming Industry
- Getting in control: how power resistors benefit motor control
- Drives and the digital twin
- Helping to characterise analytical sensors
- VFD specifically designed for CO2 refrigerant condensing systems
- New servo drive and motor package increases performance and minimises footprint
- Control 128 axes of motion over Ethernet/IP with Intellidrives IMAC motion server
- Drive controllers and filters minimise power losses in high speed machine tool spindles and turbo blowers
- Drives achieve an iFLY high
- Stober collaborates in the drive to make more mobile ventilators
- Miniaturised controller from Maxon
- Stober collaborates in mobile ventilators drive
- Robotics on the move
- Single axis servo motor controller brings Industry 4.0 technology to you
- Automation and drive technology controls movements of new stage setting
- Improve the ROI on your drives installation
- IT meets OT with new generation of Lenze controllers
- Servo drive features machine learning
- Unidrive goes multi-protocol
- Acquisition of Invertek Drives will lead to continued growth
- Suppress interference to ensure drives work smoothly and safely
- How to configure an EPOS4 Positioning Controller using EPOS Studio
- Microstepping drive for distributed I/O system
- Windows 10 support for ORION controllers
- Suppress interference and ensure your drives work safely and in harmony
- Suppress interference and ensure your drives work safely and in harmony
- Suppress interference and ensure your drives work safely and in harmony
- AC micro drives offer outstanding performance and flexibility
- Benefits of sensorless closed loop control
- High performance drive controllers
- Kingston Engineering marks its Centenary Year
- ABB launches UK-wide VSD hire fleet
- Danfoss announces first DrivePro Life Cycle partners
- Full featured microstepping drive is a real space saver
- Island residents rely on drives for clean water
- Micro stepper motor and drive certified for hazardous areas
- Play it safe with the SD6 drive controller
- Marine certifications for Yaskawa drive
- Modular, compact controller for vehicle auxiliary drives
- More than start and stop
- Motion control key for 3D laser mapping application
- New microstepping drive range with multiple communication options
- Control Techniques enlists world’s strongest man
- Inverter helps malt maker improve its productivity
- Material facts
- Intelligent stepper is ATEX certified
- The everyman guide to motion engineering
- Lenze boosts training across its drive and automation platform
- Danfoss shows how to ‘Do it Differently’ at Drives & Controls
- OEM uses machinery drive to improve boiler range efficiency
- Miniature servo drive packs a big punch
- Danfoss celebrates 50 years of AC drives manufacture at Drives & Controls
- Discover the ACS motion control solutions at the PI booth at Drives & Control 2018
- Haptic feedback for telerobotic applications
- Component compatibility can make or break a good system
- Lenze celebrates being a driving force in UK industry for 70 years
- Cutting edge accuracy with Polaris CNC system
- Danfoss delivers control without wires
- Yaskawa releases new mobile apps and wizards
- Custom drives bring machines to life
- Racing small-scale formula cars
- Microstepping drives for step and direction control
- Invertek Drives starts work on new 5,500m2 factory
- Servo drives key on ejection seat test rig
- Yaskawa continues to invest in Europe
- New online shop for motors and drives
- The miniature servo controller for extreme conditions
- Performance benefits for microbial air sampler
- Tiny servo drive offers 5000W continuous power
- Mclennan appointed exclusive UK and Ireland sales partner for Phytron
- Siemens strengthens Large Drives network through partnership with Indrico
- Precise actuation on compact blood analyser
- Mclennan safeguards manufacture and supply of SmartDrive D- and DM-series Eurocard stepper drives
- Motion and automation controllers explained
- Machine configuration with intelligent drives
- Invertek sells one millionth variable frequency drive
- Pump reliability improved with variable-speed drive and motor upgrade
- Configure high-speed drives from your sofa
- stepSERVO range expands further
- Upgraded Eurocard stepper drive now offers microstepping and higher performance
- Why the industry needs new positioning controllers
- A practical approach to servo loop tuning
- Packaging with high speed and quality
- Emerson sells Control Techniques and Leroy Somer to Nidec
- Danfoss drives roadshow coming to a location near you
- Improving move and settle times with a machine or payload that shakes
- Microstep drive for OEM applications
- Compact power for motion control tasks
- Drives range extended to 800kW
- anfoss wins Environmental and Energy Efficiency Award
- Eaton’s automation technology for grain processing
- Advanced motion control optimises laser and mechanical micro-drilling
- Drives save energy in mushroom production
- Lenze at the Drives & Controls Exhibition
- MACK drive system reduces system costs
- Theatre drives simulate football on a vertical pitch
- Eriks advises businesses to get ahead before MEPS changes in January 2017
- Drives now have a PROFIsafe option
- Variable speed starter now offers CANopen option
- ABB smartphone App eases drive tuning
- Converting from DC control to AC variable speed drives
- PCB drive solutions for electric motors
- Optridrive Elevator provides comfortable patient transit
- Optridrive Elevator provides comfortable patient transit
- Parker inverters help fuel energy storage to support EV rapid charging development project
- Fan and pump inverter resets performance benchmarks
- Steel maker improves roller table reliability with AC drives
- Marine type approval for Unidrive M
- Parker AC30 drives achieve DNV certification
- Parker's AC30 helps to mitigate flooding in caravan park pumping application
- Faster positioning of 1 tonne beams
- Mclennan launches new website for precision motion control
- Siemens brings its Integrated Drive Systems roadshow to the UK
- LG Motion delivers 6-axis vacuum compatible positioning system to AWE Aldermaston
- OEM offers dairy farmers 60% energy saving using variable-speed drives
- PCB cards offer an alternative for position control
- Variable speed starter is new option for motor control
- Energy and CO2 savings at your fingertips with toolkit app
- Halting harmful harmonics
- Custom design motion control system drives biomedical innovation
- Vacon now part of the Danfoss Group
- Danfoss is keeping World Cup cool
- Beckhoff becomes a member of the Manufacturing Technology Centre
- Service robot scales negative slopes
- Bosch Rexroth joins the Manufacturing Technology Centre
- Direct torque control
- Drives for Formula Student electric powered vehicle
- REO announces new partnership with Invertek
- Control Techniques gets green light for new tech lab construction
- ACOPOSmotor sets new standards for decentralized motion control
- Motor controllers for Formula Student electric vehicle
- Schneider Electric launches fixed price drive repair service
- The Switch to be acquired by Yaskawa Electric Corporation
- Helping Bentley and Jaguar Land Rover to move ahead in braking research
- Industry warned of grey repair threat to hydraulic and electronic drives
- Advances in drives technology
- Integrated drive systems: the Holy Grail for industry?
- Motors and drives
- Vacon Open - the Finnish Challenge tour in Hyvinkää
- Component manufacturer addresses safety and sustainability issues
- Getting more from drive technology
- Invertek challenges gamers to feel the force
- SEW Eurodrive completes move to new premises
- Advanced motion control system simplifies design of modular printing machinery
- Motion control components at Southern Manufacturing
- High-power drive rack provides up to 30 A for brush, brushless or stepper motors
- Control Techniques celebrates its 40th anniversary
- Automation increases roof truss productivity
- The efficiency drive for better motor control
- Vacon continues Alpine Ski Team cooperation
- Compact drives with option board and heat sink
- Speedy drive specification
- Custom motion system for sampler manipulator
- Drive hire service set to take off
- Encapsulation adds ingress protection to drive peripherals
- Extended range of DC controllers
- Programming software and motion modules certified compliant with PLCopen
- Driving a revolution in injection moulding
- Microstep evaluation kit built on motor, control and drive
- New Atlas motion amplifier is multi-talented
- ABB's drive recycling scheme achieves record total
- High performance microstepping drive
- Stepper manufacturer appoints LG Motion as distributor
- Enhanced thyristor power control
- Mclennan adds JVL Industri Elektronik A/S motion products to range
- Enabling the UK as a high technology hub
- SoftStart UK continues to expand staff, expertise, and certifications
- New solutions for integrated motion use less energy
- Generate motion programs directly from your CAD drawing
- EtherCAT I/O is tightly integrated into Aerotech's A3200 automation machine controller
- Motion control with Ethernet interface
- Sub-miniature drives
- New Applied Motion Products ST Configurator set-up software is available from McLennan
- Precisely align and integrate your data acquisition and motion control
- Integrated drive-motor simplifies cabling and frees up panel space
- Motion control
- Applied Motion Product's ST Configurator set-up software is available from McLennan
- Digital control boards enable cost-effective integration
- Energy saving above and beyond the electric motor
- ABB makes major investment to support Imperial's teaching facility
- New website for affordable motors and inverters
- All change for motor control as more engineers outsource
- Champions of British engineering
- Intelligent drives at the heart of printing machinery
- Wind turbine gearbox production accelerated
- Peripheral drive components
- Developing with B&R Automation Studio and EPLAN Electric P8
- Drives and controls EPLAN macros from SEW Eurodrive
- On-machine motor controller simplifies installation and saves space
- All-in-one stepper motor terminal permits direct connection of powerful steppers up to 8A
- Servo motion control systems
- The Lenze online Advent Calendar is all about motion centric automation
- Motors and inverters merge in servo actuators
- Trio ARMS new Motion Coordinator
- Energy saving
- Integrated brushless motor
- Maximise your drives
- From basic to advanced motion applications
- Motion control helps to shape the future
- Databank integrates simplifies maintenance
- Motion control
- Why buy starters when you could hire them?
- ABB variable-speed drives ensure clean air at Q-Park car park
- Eaton and Phoenix Contact sign cooperation agreement
- Mclennan launch new range of flexible intelligent microstepping drives
- Meltech cuts costs and maintenance on inline plastics coiling machines
- New resource guide brings together Aerotech's nano Motion Technology positioning mechanics and advanced motion controls
- Hybrid motor starters in a compact package
- Economy drives from Motor Technology
- EtherCAT for Trio motion coordinator
- Motion control
- Versatile, second generation controller is 94% efficient
- Accurate point to point motion
- Country park powered by Archimedes screw
- Small scale hydro supplies the grid
- What does the future hold for British engineering and manufacturing?
- ATG joins ABB's System Integrator partner programme
- The drive for precision geo-positioning
- Real-time Ethernet
- Servo drives
- Aerotech launches new MotionPAC Programmable Automation Controller at SPS/IPC/DRIVES
- Novel mini driver can be retrofitted onto stepper motors
- ACOPOSmulti modules now up to 120kW
- Motion Control
- Motion systems
- Red Drive now available for DC brushless servo motor control
- The drive to maintain harmony
- Traditional slide rule simplifies energy saving
- Develop multi-axis motion solutions in one seamless environment
- Mclennan's motion control range grows with new Allied Motion product lines
- Drives support
- Electric automation systems and components
- Energy efficient servos with many Ethernet standards
- Drives and motors
- Drives help reduce energy usage on flight simulators
- Fully packaged intelligent drive is in the box seat
- New plug-in module controls up to four servo axis
- Helping OEMs bring motion systems to market faster
- Warm welcome for IEC 61439 and also a warning
- Manufacturing and engineering shows confirm seminar programme
- Compact drive meets energy saving needs
- Improved control on stepper motors used as brushless servos
- Driving the largest theme park in Latin America
- IMO launches first drives scrappage scheme
- New president for Control Techniques
- I/O system combines compact design with high functionality
- Drives finally recognised as an important green technology
- Precision positioning at Diamond Light Source
- Get 20 percent off the new IET Drives and Controls Handbook
- Moog's Technology Moves Retractable Roof for Wimbledon's Centre Court
- Schneider Electric is a driving force behind Wimbledon roof
- Expansion for virtual distributor
- ABB launches machinery drive with IP66
- Automation engineers must ensure long-term, multi-facetted systems stability
- Drives and servos
- Modular motion and machine controller
- Motion platform puts controller on the PLC rack
- Recreating category 5 hurricane conditions
- Distributor of the Year 2008
- Simon Smith returns to Aerotech to head up new European Control Systems Division
- B&R puts a PC in a drive
- Encoder for motor drive package
- Multi-axis control for electric drives
- Positioning and motion
- Energy saving
- B&R moves into inverter market
- Combining simplicity with versatility
- Compact vector drive is built for integration
- Easy switch to Ethernet
- If it's fixed speed, it's the wrong speed
- Major tidal turbine contract for ABB
- Microstepping drives increase capability
- Softstart UK wins national award
- Tiny drive punches above its weight
- Energy efficiency award
- CANopen intelligent drive
- Compact drive for stepper motor control
- Increase productivity and reduce costs
- Putting ideas into motion
- Stepper drive provides software control option
- Integrated servo and motor eases installation
- Automation solutions
- Bottling solution is in the bag
- Plug-in drive has CANopen
- Servos join the Ethernet revolution
- Stepper package offers increased performance
- Servo products designed to meet military requirements
- Fast and precise positioning for dynamic applications
- Now it's easier than ever to develop motion sequences
- Speed control for single phase motors
- Making motion precise and jerk-free
- Controller makes MUSIC
- Maxon is boxing clever with intelligent compact drives
- Motion system on a single chip
- Intelligent stepper controller provides servo functionality
- New drives can mount on old fixing points
- New small size delivers all-in-one full featured integrated motion control
- Truly intelligent linear package
- Easy introduction to decentralised drive technology
- Fast solution for vertical conveying
- Designing and building complete servo systems
- Simple solution for positioning system design
- All the benefits of brushless DC drives over a wider speed range
- DC drives upgrade propels Navy development forward
- Digidrive SK range gets a boost to 132kW
- Drives get bigger and smaller
- Ethernet Powerlink brochure
- Integration of servo drives
- Patented control chip set to revolutionise integrated motion
- Leroy Somer rethinks the variable speed drive
- Motion systems
- Servo drives for high power motion control
- Simplifying machines for OEMs
- ABB launches into the servo market
- Inverters bring new life to general purpose market
- Servos supplied ready to drive
- Torquing the talk
- A revolution in servos
- Award winning compact drive
- Compact four quadrant DC drives save energy
- Electric drives range is all about choice
- Extended power range for servos
- Highly flexible stepper driver
- New technique offers improved stepper control
- Servo drives and motion controllers
- The integrated approach to advanced motion control
- Boosting food industry productivity
- Cool Muscle is a smooth mover
- New electronic line shaft
- Servos are smaller and faster
- Drives cater for all applications
- Power for simulation systems
- Driving British films forward
- Sensorless commutation
- Drives get extended power and washdown variants
- High speed, sub-micron positioning
- Single phase soft start/stop
- Boosting CNC productivity
- Direct drive motion platform for laser machining
- Modern retrofit keeps the presses rolling
- Drives go large
- Driving forward with new inverters
- Dual networking standard for servo drives
- Fast, smooth stopping with DC injection brakes
- General purpose inverters
- Integrated servo motion package
- Taking the engineered systems approach
- Unidrive SP is now Sercos-B compliant
- Packaging chocolate pralines
- Expanded range of servo gear motors
- Single source for comprehensive soft start options
- Single source for soft start options
- New soft start company hits the ground running
- Small, low cost drive is feature packed
- UL approved braking resistors
- Softly softly for Bombay water treatment
- Automation platform simplifies integration
- Precision motion control solutions
- Sawmill upgrades with Undrive
- The drive to test wind turbines
- Ultra compact integrated servo