As more breweries move from manual brewing to automated production, the control system has become one of the most important parts of modern brewing equipment.
At the center of every automated brewery is the PLC (Programmable Logic Controller) — the system that receives signals from sensors and controls pumps, valves, motors, and heating.
For breweries using Siemens automation, one common question is:
Should you choose the Siemens S7-1200 or the Siemens S7-1500?
The answer depends on your brewery’s size, automation level, and future expansion plans.
What Does the PLC Do in a Brewery?
You can think of the PLC as the brain of the brewery.
It performs two main jobs:
- Receives signals from sensors
- Sends commands to equipment
For example, the PLC can:
- Start or stop pumps
- Open or close valves
- Monitor tank temperature
- Control liquid level
- Adjust motor speed
Without a properly selected PLC, even high-quality equipment cannot run efficiently.
Understanding I/O Signals
When selecting a PLC, the most important factor is the number of I/O points required.
I/O means:
Digital Signals (ON/OFF)
These signals only have two states:
- ON / OFF
- OPEN / CLOSED
- START / STOP
Examples:
- Pump start command
- Valve position feedback
- Emergency stop buttons
- Tank level switches
Analog Signals (Variable Values)
These signals measure changing values.
Examples:
- Temperature sensors
- Pressure transmitters
- Liquid level sensors
- Variable speed pump control
In simple terms:
- Digital = Is it happening?
- Analog = How much is happening?
Siemens S7-1200: Best for Small and Mid-Size Breweries
The Siemens SIMATIC S7-1200 is designed for compact automation systems.
It offers:
- Reliable performance
- Easy programming
- Flexible expansion
- Lower investment cost
For breweries between 500L and 5000L, the S7-1200 is often an ideal choice.
Typical systems may include:
- Brewhouse vessels
- Fermentation tanks
- CIP system
- Transfer pumps
- Pneumatic valves
- Temperature sensors
A brewery of this size usually needs:
- 80–150 digital points
- 20–40 analog points
The S7-1200 can easily handle this range while still allowing room for moderate expansion.
Siemens S7-1500: Best for Larger Automated Breweries
The Siemens SIMATIC S7-1500 is designed for more advanced industrial automation.
Compared with the S7-1200, it provides:
- Faster processing speed
- Larger memory
- More communication options
- Stronger network capability
- Better long-term scalability
For breweries with:
- 2000L+ brewhouses
- Multiple fermentation tanks
- Automatic CIP
- Recipe control
- Remote monitoring
- Data logging
the S7-1500 becomes the better solution.
Larger systems can require:
- 300+ digital points
- 100+ analog points
The S7-1500 can manage this more smoothly and support future expansion.
Simple Comparison
| Feature | S7-1200 | S7-1500 |
|---|---|---|
| Best for | Small breweries | Large breweries |
| Cost | Lower | Higher |
| Programming | Simple | Advanced |
| Expansion | Moderate | Excellent |
| Processing speed | Good | Very fast |
| Future upgrades | Limited | Strong |
The Most Important Question
Many customers ask:
“Which PLC is better?”
The better question is:
“How much automation does my brewery need?”
Before selecting a PLC, it is important to:
- List all tanks and equipment
- Count every sensor
- Count every valve and motor
- Calculate total I/O points
- Consider future expansion
The control system should match your brewing process — not the other way around.
Our Recommendation
At TIANTAI, we do not recommend a PLC based only on brewery size.
We carefully evaluate:
- Brewing process
- Tank quantity
- Valve logic
- Automation level
- Expansion plans
Then we select the right Siemens platform for your project.
In general:
✅ S7-1200
Best for small and medium breweries with standard automation.
✅ S7-1500
Best for larger breweries with advanced control and future expansion.
Final Thought
The best PLC is not always the most expensive one.
The best PLC is the one that fits your brewery today — while supporting your growth tomorrow.
If you are planning an automated brewery project, choosing the right control system at the beginning can save time, labor, and operating costs for years to come.
If you want to discussed more, please contact me.
Project manager: gbrew@cnbrewery.com
Email: gbrew@cnbrewery.com