Over 20 Years of Partnership: The Success Story of Privatbrauerei Zwettl & corosys

The long term collaboration between Privatbrauerei Zwettl and corosys GmbH is a remarkable example of a successful partnership and mutual trust in the brewing industry. For over two decades, both companies have worked hand in hand to optimize brewing processes and enhance quality.

The Beginning of a Long-Term PartnershipIn November 2002, Brewmaster Heinz Wasner attended BrauBeviale in Nuremberg, one of the industry’s most important trade fairs. At the fair, he came across a system at the booth of the then-young corosys GmbH, which appeared to be a carbonator. His interest piqued, he initiated a conversation with Stephan Dittrich, Managing Director of corosys, laying the foundation for a partnership that continues to this day.
First Joint Projects
On February 5, 2003, Zwettl Brewery ordered a CWD 80 cold water degassing system and a Carboblender BCS DN65 from corosys. This investment demonstrated trust in corosys technological expertise. By May 16, 2003, the systems were successfully commissioned. The degassing system has since produced de-aerated water, while the carbonator enabled precise carbonation of beer and mineral water on-site. These technologies improved the product quality and production processes at Privatbrauerei Zwettl.

Expanding the Partnership and Achieving Success Together

Over the years, the collaboration deepened. Zwettl recognized the added value of corosys tailored solutions. On March 20, 2012, M&L Consulting GmbH, in partnership with corosys, was awarded the contract to deliver a comprehensive new beer filtration system. This included blending, carbonation, a flash pasteurizer, a CIP (Cleaning-In-Place) system, and a new pressure tank cellar. This large-scale project marked a significant milestone in the brewery’s modernization.

Detailed Project Phases
Phase I: March to May 2012 – Preparation and Energy Supply
Initial steps focused on laying the groundwork for the new KEG filling line. This included the construction of new water tanks to optimize the water supply and the structural work for the new energy center, which housed a steam boiler and transformer station.

Phase II: May to August 2012 – KEG Line and Energy Center Installation
The installation of the new KEG filling line increased Zwettl’s bottling capacity, meeting growing market demands. The energy center efficiently powered the production facilities.

Phase III: June to October 2012 – New Filtration Building and CIP System
The construction of the new filtration building and the installation of a state-of-the-art filtration system by M&L Consulting and corosys marked a pivotal step in enhancing beer quality.

Phase IV: September to November 2012 – Expansion of the Pressure Tank Area
The construction of a new building section for the pressure tank cellar created additional space, allowing for more flexible production and improved storage capacity.

Phase V: October 2012 to June 2013 – Expansion and Modernization
The old pressure tank cellar was decommissioned, and a new area was developed. The installation of a new flash pasteurization system ensured optimal pasteurization of Zwettl products.

Phase VI: July to August 2013 – Finalization
Interior work in the production area was completed, and the technical equipment for the production and storage halls was finalized, improving working conditions for the employees.

Automation & Modernization
On September 19, 2017, corosys was commissioned to automate the existing fermentation cellar. The implementation of automation technologies allowed for precise control and monitoring of fermentation processes. Sensors and software were integrated to track temperature, pressure, and other relevant parameters in real-time, ultimately reducing production costs.

Further Optimization: September to October 2020
A server migration and an upgrade to ProLeiT V 9.7 were completed, enhancing process control and monitoring while preparing the infrastructure for future expansions.

Current Developments and Future ProjectsIn recent years, the partnership has gained further momentum with several significant projects:

January 2023 – Automation of the Yeast Cellar and Wort Transfer
corosys was tasked with automating the yeast cellar and wort transfer, including yeast dosing based on cell count measurements. These advancements enable precise control of the fermentation process. Automated yeast dosing ensures the optimal amount of yeast is used for each brew, improving consistency and quality.

February 2023 – Wireless Automation for Tanker Cleaning
To improve efficiency and safety in tanker cleaning, a wireless automation system was installed. This reduces manual effort and minimizes the risk of operator errors. The wireless control system offers flexibility and can be easily integrated into existing processes.
May 2023 – Integration of Wastewater Treatment Automation into the Process Control System
The automation of the wastewater treatment plant was migrated into the existing process control system. This allows centralized monitoring and control of all production and cleaning processes within the brewery, enabling faster detection and resolution of potential issues.

March 2024 – A New Milestone for the Filling Line
corosys was awarded the contract for delivering the complete process technology for the new filling line, including a pressure tank cellar, CIP system, flash pasteurization unit, water deaeration, and media supply, as a turnkey project.

Conclusion

The success story of the partnership between Privatbrauerei Zwettl and corosys demonstrates how long-term collaboration, mutual trust, and a commitment to innovation can achieve remarkable results. Both companies have evolved together, combining traditional brewing craftsmanship with cutting-edge technology.

This synergy enables them to meet high customer expectations while operating sustainably and efficiently. The joint successes of the past two decades provide a solid foundation for future projects.