Summary

AMPS Industrial Controls executed a full programmable logic controller (PLC) retrofit for Dildo Brewing Co. in Newfoundland, Canada, in collaboration with its customer, ControlTec, Inc., a specialist in building controls and control systems for the craft beverage industry located in Pittsburgh, PA. The project replaced an unsupportable legacy Siemens control system with a unified Unitronics UniStream US15 HMI+PLC platform. This control overhaul resolved major software bugs and user-interface clutter, leveraging EtherNet/IP and IO-Link protocols to streamline the operation of over 100 control valves and multi-vendor sensors.

The Company

Dildo Brewing Co. & Museum is a prominent craft brewery located in Dildo, Newfoundland and Labrador, Canada. To execute the retrofit, they partnered with AMPS Industrial Controls, an Ohio-based system integrator and authorized Unitronics distributor with over 30 years of experience in custom control panel fabrication and turnkey automation and ControlTec, Inc., a specialist in building controls and control systems for the craft beverage industry located in Pittsburgh, PA.

The Challenge: Overcoming Overseas Programming and Cluttered HMI Architecture

Dildo Brewing Co., located in Dildo, Newfoundland, originally purchased a pre-packaged Siemens craft brewing system bundled alongside their overseas-manufactured brewing vessels and equipment. However, the brewery faced persistent operational issues for about a year following installation. Because the company that designed and programmed the system was located overseas, a severe language barrier and time-zone mismatch made effective troubleshooting nearly impossible for the end user. 

The primary technical challenges stemmed from the pre-packaged Siemens programming and the lack of localized developer support. The human-machine interface (HMI) was heavily cluttered with unnecessary data points and functions that the operator did not need, resulting in a rigid interface that could not be easily customized. To get the brewhouse operating as originally planned, the client required a North American-based automation partner who could deliver local system support, properly troubleshoot the software, and modify the application to meet specific operational workflows. 

Dildo Brewing already had another successful brewing system based on Unitronics UniStream, previously developed by AMPS and ControlTec. For this retrofit, they wanted to remain within the Unitronics ecosystem.

The Solution: Unified Unitronics US15 HMI+PLC Control Architecture

AMPS designed a new control architecture centered on the Unitronics UniStream 15.6" (US15-B10-B1), providing a powerful combination of PLC logic and a big high-resolution touchscreen in one device.  To handle the brewhouse's extensive field requirements the hardware configuration included multiple I/O expansion modules, including transistor and I/O, specialized PT100/RTD temperature inputs (UIS-04PTN), and IO-Link modules.

The completed Unitronics hardware bill of materials included:

• Controller: Unitronics UniStream 15.6" Built-in HMI + PLC (US15-B10-B1) 
• I/O Modules: Two UID-1600 digital inputs, two UID-0016T transistor outputs, three UIA-0006 analog modules, and three UIS-04PTN RTD inputs connected via a UAG-CX-XKP300 expansion adapter 
• Networking: Three Unitronics EtherNet/IP IO-Link Masters (ULK-EIP-8AP6) 

This unified hardware configuration allowed the system integrators to easily consolidate a massive volume of signals. The retrofitted control system hardwires 7 Variable Frequency Drives (VFDs), 10 modulating valves, 8 RTDs for precise temperature loops, status lights, and numerous miscellaneous digital signals directly to the PLC's expanded I/O. 

Control Functions: Programmed in UniLogic

Utilizing Unitronics' single, intuitive UniLogic software suite, AMPS engineers programmed automated control logic to manage the high-density physical layout of the facility. Rather than running thick bundles of traditional point-to-point field wiring back to the main control panel, the automation professionals took advantage of advanced industrial networking protocols to handle the brewery's hardware components: 

• IO-Link Sensor Integration: AMPS interfaced the UniStream PLC with a distributed array of IFM-branded liquid sensors, pressure transducers, and flow meters. These devices connect directly to the Unitronics IO-Link Masters, drastically reducing field wiring requirements and delivering granular device-level diagnostics. 
• Valve + VFD Communication via EtherNet/IP: The highly automated brewhouse features over 100 control valves. To manage this complex network efficiently, AMPS integrated an Aventics G3 pneumatic valve stack controlling 94 valves. This valve stack communicates directly with the UniStream PLC using native EtherNet/IP protocol, optimizing response times and eliminating manual termination errors.
  The logic also coordinates 7 VFDs and 10 modulating valves to maintain precise process conditions.
• Automated Sequencing: Custom logic handles critical brewing phases, including Mash-In, Vorlauf, Kettle Transfer, and Whirlpool functions

HMI—Designed in UniLogic

The legacy HMI was heavily cluttered with unnecessary data points and functions, resulting in a rigid interface that could not be easily customized.
Using the free UniLogic HMI editor, AMPS easily created a streamlined, vessel-centric interface that eliminated the clutter of the previous system.

• Vessel-Based Navigation: Dedicated screens for the Hot Liquor Tank (HLT), Mash Tun (MT), Lauter Tun (LT), Boil Kettle (BK), Whirlpool (WP), and Clean-in-Place (CIP) systems.
• One-Touch "Function" Buttons: Each vessel page features context-aware buttons that trigger complex automated sequences—such as opening specific valves and starting pumps—to simplify the operator’s workflow.
• Real-Time Diagnostics: The interface provides granular feedback, including flow rates in LPM, temperature setpoints, and valve status indicators.

• Safety & Alarms: A comprehensive Alarm Status Viewer and History page allows operators to quickly identify and resolve issues like "Low Level" or "Liquid Empty" conditions.

Remote Access & Communications

A critical upgrade provided by the Unitronics retrofit was the inclusion of secure remote access capabilities. The UniStream platform natively supports Ethernet connectivity and modern industrial communication protocols without requiring external gateways. This enables the engineering team at AMPS to provide secure real-time troubleshooting and run software updates via VNC+ VPN.

Benefits / Results: Streamlined Operations and OEM Peace of Mind

The transition from legacy Siemens hardware to the custom Unitronics UniStream automation solution yielded immediate, quantifiable improvements: 

• Significant Wiring Reductions: Integrating distributed IO-Link Masters and EtherNet/IP valve stacks slashed physical cable installation time and simplified panel building costs. 
• High-Performance HMI Responsiveness: Transitioning to custom, vessel-specific touchscreens eliminated screen clutter and accelerated daily brewing cycles. 
• Localized, Tier-Free Support: Technical support is fully backed by Unitronics' tier-free expert assistance and AMPS' application engineers. 
• Scalable and Future-Proof Programming: The control application runs the brewhouse perfectly and is structured to accommodate straightforward future expansions or code modifications. 

Reflecting on the success of their first production day following the Unitronics control retrofit, the end customer at Dildo Brewing Co. shared:

"Honestly, I didn't realize how much tension I've been holding onto the last year. All washed away about 30 min ago!"

AMPS lead engineer, Alex Foulke, said:

“The system is controlling the brewhouse perfectly and is set up for easy future modification. The customer was VERY happy with the result!”