Sulwath  Brewery - Micrologix Bottling Machine repair and upgrade

We were recently approached by a local brewery that could no longer operate efficiently due to an ongoing issue with a beer bottle filling machine. The machine was no longer supported by the OEM manufacturer and the brewery was facing a large investment for a new machine.  During our first visit we managed resolve the reason for the failure and get the machine back into operation.

Further to the initial breakdown, we were made aware of a smaller machine that had been shelved due to a fault. This bottler contained an older Micro-1 PLC. This was faulty and there was no way to retrieve the original programme code. The machine was moved into our workshop where it received a newly programmed Siemens LOGO PLC. We are also upgraded all the electrical wiring, pneumatic and hydraulic hoses. the machine was re-installed and with a small amount off commissioning was operational the same day.

Now that the smaller machine was available for backup, we could now rebuild the larger machine. We took a backup of the Allen Bradley MicroLogix PLC and Maple Systems HMI prior to starting our rebuild. All worn out hoses; air lines; solenoids and sensors were replaced. We upgraded the electrical supply by installing RCD protection and a 3 pole switched isolator. Upgraded lighting was installed in the bottling chamber to allow the operators to easy identify fill levels and adjust the system as required.

During the rebuild it was noticed that a number of the buttons on the HMI were failing intermittently. We managed to source a replacement HMI and download the program.


With the assistance of the brewery staff during commissioning, we had the machine back in operation in a very short period of time. 

All of the above is being completed at a fraction of the cost of a new bottling machine.