The upgrade of the automation system at the Malthouse of Athenian Brewery’s factory in Sindos, Thessaloniki.

Complete digitalization of critical production processes. Reduction of human error and establishment of full control and traceability conditions for one of the most demanding stages of beer production — the transformation of barley into malt.

Athenian Brewery, a proud member of the HEINEKEN Group and the largest brewery in Greece, has consistently invested in modernizing its infrastructure to ensure safety, quality, and efficiency. With production plants in Athens, Thessaloniki, and Patras, the company has maintained a dominant market presence for over 60 years.

In 2024, following a competitive tender process, the company entrusted AS HELLAS with a major project in the brewing sector: the automation upgrade of the Malthouse at its Thessaloniki plant. The goal was to fully digitize critical production processes, minimize human error, and ensure complete control and traceability during one of the most demanding stages in beer production — transforming barley into malt.

The project came with significant technical and operational challenges:
Integrating legacy systems from past decades with new technologies.
Ensuring strict safety protocols in confined or sensitive environments (e.g., underground silos, steeping tanks).
Performing tests under real production conditions, safeguarding both personnel and equipment.
Managing hundreds of control points, requiring detailed coordination and testing.

AS HELLAS’ CONTRIBUTION

AS HELLAS provided turnkey engineering, automation, and commissioning, delivering a fully integrated solution:

• 85 new automatic ORBINOX slide gates, sensors, and cameras for real-time monitoring of the germination chambers.
• PLC and SCADA system upgrades, with full migration to WinCC V8.0 and seamless integration of older platforms.
• Development of 107 new automated functions, supporting over 850 recipes for routing materials from silos to destinations through complex routes.
• Centralized control and remote supervision via a high-availability (redundant) SCADA system with multiple clients and real-time visualizations.
• Network infrastructure upgrades, including optical fiber, local HMIs, and control room displays, ensuring seamless communication across the facility.
• The implementation followed the strict safety standards and schedules set by HEINEKEN, with project completion by January 31, 2025.

THE RESULT

The new system empowers Athenian Brewery with:

• Maximum operational safety across the plant.
• Elimination of manual errors via full automation.
• Increased productivity and ease of operation.
• Real-time monitoring of energy and water consumption.
• Centralized production visualization and diagnostics.
• Higher malt production quality, through consistency and traceability.
• Online support and remote troubleshooting, reducing downtime.