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Carlsberg Leverages IoT to

Scale Digital Transformation
Across Global Sites
The Partnership with Autoware Enables the Brewing Company
to Advance Their Design, Deployment, and Scaling of Real-time
Performance Monitoring

Carlsberg is a Danish brewing

company with a global reach and
When it comes to modern a rich heritage
manufacturing, production Founded 172 years ago, Carlsberg is a Danish
data is essential to improving Brewing company with a global presence that is
operational efficiencies and one of the world’s leaders in the brewing industry.
adding business value. From They operate 78 brewing facilities around the
world, and with over 140 brewed beverages—
reducing equipment downtime
including core beers, specialty and craft beers,
to increasing throughput, the alcohol-free brews, and local brands from
right technology can help numerous countries—Carlsberg has a diverse and
leverage data to unlock value globalized beer portfolio.
across the enterprise. Learn how
Unlike other industries, the brewing industry
one manufacturer used PTC’s has only recently begun implementing digital
ThingWorx and Kepware to solutions to optimize manufacturing processes.
reimagine beverage production Like many manufacturers that operate sites in
and improve internal processes, different regions of the world, Carlsberg faced
some challenges in standardizing how various
all while maintaining their
sites tracked production data.
commitment to innovation and
sustainability. Carlsberg had been exploring digital solutions
for over a decade, looking at ways in which they
could enhance their manufacturing processes
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and performance measurement while improving assess production performance across different
overall equipment effectiveness (OEE). Despite facilities via real-time data and alerts.
having a full manufacturing execution system
(MES) in 10 factories, Carlsberg wanted a lighter To develop the application, Autoware utilized
solution that would scale quickly and easily, and Kepware, a software that automatically pulls data
ultimately help them standardize data collection from a variety of automation devices and software
across their global facilities to improve production applications and aggregates it into a uniform data
performance. They recognized that with more model. In addition, Autoware used ThingWorx, an
consistent data collection methods, they could end-to-end industrial IoT platform which provides
optimize machine performance, decrease visibility into production and asset health with real-
unplanned downtime and costs, and increase time data analytics and a rich array of insights and
throughput. production reporting. Together, the technologies
allowed Carlsberg to monitor machine data and
project it onto dashboards, laying the foundation
Carlsberg partners with Autoware of their digital transformation journey.
to leverage IoT solutions and
improve OEE The data will give operators a clear understanding
of how the line is performing against targets,
Carlsberg worked with Autoware, an Italian
while real-time alerts help them quickly identify
software company focused on implementing
and resolve any production issues. Similarly,
digital transformation in the manufacturing sector,
some floor operators will be able to use tablets
as the technology partner to help them begin the
equipped with an app that leverages ThingWorx
process of improving their data collection and
data to track the downtime of a specific machine
operations. To do so, Autoware leveraged PTC
and proposes the reason in real time; the operator
technology to design an IoT-based application for
can then confirm next actions to take, even from a
real-time performance monitoring. The application
remote location in the facility.
could be used by machine operators to easily

Autoware promotes innovation in the manufacturing sector by

integrating systems with creative Industry 4.0 solutions. As a long-
time PTC partner with deep expertise in manufacturing technology,
Autoware was the ideal choice for assisting Carlsberg through their
revitalized digital journey. Ready to pursue success, Autoware’s
team quickly integrated into the project to help design, deploy, and
scale a new IoT solution across the enterprise.
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Autoware’s solution helps Carlsberg application’s data standards. Kepware collects

standardize and scale with efficiency data from the PLCs throughout the regional sites,
and ThingWorx utilizes the data from Kepware and
Carlsberg had already laid much of the visualizes it for real-time monitoring and diagnosis
groundwork toward standardization across at each site.
facilities, but their new solution would better
address the gaps created by legacy equipment The team chose a cloud-based architecture for
and variations in data collection, architecture, the new solution, which offers some significant
and software. Importantly, the standardization of benefits over the previous on-premise solution
data and metrics will allow Carlsberg to evaluate in their other facilities. A cloud-based solution
machine performance and productivity relative makes it easier to evolve the system and add
to other factories. After launching in just three new features. Any updates to the application
months, it will also help satisfy the need to scale only need to be deployed once, and the cloud-
quickly across multiple facilities. based architecture makes those same changes
immediately available to any site. At the same
“Our goal was to develop an application that time, they can make some site-specific features
provides a common standardized view of available only to certain locations and deploy
production data to the client,” says Luigi De them at others later.
Bernardini, CEO of Autoware. “Having that
common view enables them to make decisions This flexibility to configure the solution as
needed—thus being more efficient and saving
on how to organize production and measure the
time—greatly improves the total cost of ownership.
efficiency of the various production sites in a very
“The footprint of the new solution is much smaller
objective way—that’s the real business value.”
than the footprint of an on-premise solution—it
Notably, Kepware was key to achieving value takes fewer resources to manage,” says Marco
and to working within a centrally configured Faltracco, Technical Lead at Autoware. “The
data environment. It allows them to import and architecture enables them to scale to so many
export configuration information and easily adapt more plants, and now they’re considering further
any particular facility’s variances to meet the expansion because it’s easy to do that,” he
continues. “In terms of total cost of ownership, it’s
much lower than having an on-premise solution.”

Carlsberg achieves improved

performance and productivity while
planning for a more sustainable future

To date, the application has been rolled out at

28 Carlsberg facilities. Eventually, the agenda
will include implementation in the remaining
breweries. While Carlsberg’s digital transformation
journey is still unfolding, they’ve already seen
clear benefits of real-time performance monitoring
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“We believe that with this kind of project, the only way to have it
succeed is to build a strong team with everyone involved and tie it
all together with the right technology.”

Luigi De Bernardini,
CEO, Autoware

throughout their business. First, they’ve seen De Bernardini. “Together, we reached the point in
improved operational procedures, as well as fewer which the whole team was skilled at their duties
line interruptions with greater visibility. Additionally, and responsibilities. In fact, our entire business
Carlsberg has experienced reduced equipment model is based on partnerships,” he explains. “We
downtime with better preventive maintenance. believe that with this kind of project, the only way
to have it succeed is to build a strong team with
Another positive outcome is the reduction of waste,
everyone involved and tie it all together with the
which positively contributes to company goals
right technology.”
around carbon emissions and sustainability.
For Carlsberg, advancing their digital journey
Notably, the power of partnership has made all
has been a confirmation of the company’s
the difference in Carlsberg’s ability to roll out their
consistent place in the brewing industry as not
solution with confidence and efficiency, which only just an innovator, but as a company looking to
stands to benefit all parties in the long run. “As a create a better, more sustainable future—and
team of partners, we worked closely and were able they look forward to partnering with Autoware for
to deploy at the last site in just a few days,” says continued success.

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