Premium Winery: Enhancing Wine Quality and Process Control with Automation

Project Goal

The primary aim of this project was to increase automation in winery operations and improve quality control by enabling more accurate, real-time fermentation monitoring. As a leader in innovation, the winery aimed to bring new academic research on continuous Brix monitoring to a commercial scale. This initiative stemmed from the need for consistent data on fermentation progression, especially at the lowest Brix measurements. The project aimed to improve insight with increased access to Brix measurements between manual tests and provide additional quality assurance during critical production phases. Remote management through automation became a necessity when wildfire evacuation orders disrupted winery operations across multiple seasons. 

The Challenge

Manual fermentation measurements are standard in the wine industry but have some limitations that include:

• Increased risk of inaccurate data points and recordings
• Limited measurement to a single point in time
• Limited data from only one location within a tank

The winery initially started with a different measuring principle to measure Brix levels and monitor fermentation to anticipate completion. However, this sensing principle was found to be inconsistent and often inaccurate within a critical Brix range (3 brix to negative brix), with readings sometimes deviating from the manual measurements by as much as two Brix units. This inaccuracy was problematic for quality control, as precise data is essential at this point in the process to determine when fermentation is likely to complete. When considering alternative methods of measuring Brix level, they used it as an opportunity to evaluate other specifications that could bring additional benefits. They decided to assess alternative solutions based on data accuracy, overall costs, and compact design.  

The winery was curious about whether it was possible to find more accurate, compact, and cost-effective options for real-time Brix monitoring during critical fermentation stages. The goal was to create an automated monitoring system with remote access to integrate with the existing TankNET® infrastructure, deliver increased data accuracy, and improve operational efficiency. 

The Solution

In collaboration with James Nelson of MeshVines, the winery sought to redesign the monitoring system. The team completed an in-depth evaluation of density monitoring solutions for winemaking and a subsequent assessment of industrial pressure transducers. The evaluation determined that the ifm pressure transducers stood out for their exceptional balance between price and resolution. The ifm solution allowed for precise, real-time data collection at a lower cost and also improved safety. The winery decided to start an initial trial of the ifm pressure sensors in 2022 by outfitting three tanks.

Why ifm?

During the evaluation phase, the team considered several real-time density measurement methods. However, they chose the ifm PI1718 pressure transducers after considering a few key factors:

• Measurement accuracy. The ifm pressure sensors delivered accurate readings even in the presence of bubbles or solids commonly encountered during fermentation that often lead to inaccuracies with other measurement principles. 
• Ability to measure large volumes of liquid. Many alternative technologies only measure small volumes of liquids, a limiting factor on large fermentation tanks. The ifm pressure sensors maintain accuracy whether there is stratification or mixing inside the tank. 
• Robust sanitary design. Without screens or sensitive surfaces, the ifm pressure sensors are designed to withstand the extensive cleaning and sanitization procedures in wineries without specialized maintenance requirements. The flush-mounted design is also less prone to microbial growth to help maintain beverage quality and safety standards. 
• Seamless data access. The embedded IO-Link technology enables a seamless flow of sensor data to existing control systems. The digital signal of IO-Link is another key component that improves measurement accuracy. 

Using the ifm IO-Link Masters with a Modbus TCP/IP gateway, the team was able to connect the smart sensor data seamlessly into the existing TankNET® control system. This infrastructure allowed for the integration of real-time Brix, temperature, and redox data into TankNET's automated fermentation dashboard. The winemakers could then monitor fermentation trends and immediately take action when necessary. This connectivity helped them gain actionable insights from sensor data by meeting the specialized requirements of the winemaking process. The precision of the ifm transducers also enabled the integration of measurements with the MeshVines API for automated fermentation modeling. 

Results

The new automation solution resulted in significant improvements in both data accuracy and operational efficiency. Key achievements included: 

• Improved Accuracy: The ifm transducers offered consistent and reliable Brix measurements, especially within the critical range where alternative brix sensors previously failed. This allowed the team to confidently monitor fermentation and take corrective action if needed. 
• Enhanced Operational Efficiency: Automation reduced the need for manual readings, allowing staff to focus on analysis rather than routine data collection. Additionally, the Grafana dashboard allowed for real-time insights into fermentation curves, enabling early intervention when issues were detected. 
• Cost Savings: Replacing the expensive alternative Brix sensors with ifm transducers led to thousands of dollars in cost reductions per sensor. Initial investments in infrastructure were also justified by the system's flexibility, allowing future integrations for additional research projects. 
• Reduce environmental impact: The real-time monitoring of changes in density data supports optimized energy use for fermentation temperature control. Access to this data helps wineries measure any reduction in energy consumption to achieve their long-term sustainability goals. 
• Increase safety & resiliency: With real-time remote monitoring and control, wineries maintain oversight from anywhere. The benefit of this feature proved to be important during wildfire evacuations across multiple seasons. Winemakers can maintain operations while prioritizing worker safety.

Following the completion of the trial, the winery decided in 2023 to scale the project, integrating twelve tanks with ifm pressure transducers and constructing custom panels for broader data collection capabilities. The final goal is to integrate the remaining tanks and complete the entire cellar by the end of 2026. 

Conclusion

This project demonstrated the potential of automation to transform winery operations by enhancing both data reliability and quality control. As James describes, “The success of this project is also a direct reflection of the winery's commitment to absolute wine quality, attention to detail, and a daring-to-lead culture.”

By adopting a forward-thinking approach and investing in scalable technology, the winery has positioned itself yet again as an industry leader in innovation. This solution not only supports operational efficiency and remote management but also provides a valuable data foundation for ongoing research efforts. Future expansions will allow for even greater precision and control, offering a model for other wineries aiming to modernize their operations.