Answer extracted from The Manufacturing IT Podcast — listen to the full episode below.
How did Stone Brewing improve operational efficiency after implementing MES software for brew house control?
Stone Brewing, recently acquired by Sapuro, achieved rapid operational gains by deploying Sepasoft MES software to control their entire brewing process and delivery system. After just 30 minutes of training, operators were independently modifying recipes, copying them, and creating new ones without requiring engineering involvement—all while maintaining zero production loss during implementation.
The speed of adoption reflected a fundamental shift in how brewers could interact with their manufacturing systems. Rather than requiring months of technical onboarding, the intuitive interface enabled beer masters to take direct control of recipe development and process adjustments.
This empowerment extended beyond simple recipe tweaks. Operators gained the autonomy to experiment with new brewing approaches and modify existing processes in real time, a capability that had previously been locked behind engineering gatekeeping. The result was faster innovation cycles without the delays of traditional engineering change requests.
Zero disruption, immediate capability
What made Stone Brewing's deployment particularly striking was the absence of production impact. Many MES implementations require a transition period where operators work in parallel with legacy systems, or where training delays push live deployment. As discussed in The Manufacturing IT Podcast, Stone Brewing achieved full operational capability without sacrificing a single production cycle.
This was possible because Sepasoft's architecture, built on Inductive Automation's Ignition platform, eliminated the need for separate systems running side-by-side. Both the HMI/SCADA layer and the MES layer operated on the same foundation, reducing complexity and cutting integration overhead that typically extends deployment timelines.
The 30-minute training threshold speaks to the usability threshold required for modern manufacturing software. Legacy monolithic systems often demanded weeks of classroom training before operators could confidently interact with the software. Sepasoft's modular design prioritized self-service, allowing operators to learn by doing rather than sitting through extended documentation cycles.
Tom Heckman — Founder and CTO, Sepasoft. With over 20 years in manufacturing and automation, Heckman started his career in the 1980s at an Allen Bradley distributorship, focusing on data collection and PLCs before founding Sepasoft in 2010. He recently stepped back from the CEO role to focus on the company's technology strategy.
The deployment also highlighted how modern MES platforms could function as innovation accelerators rather than just compliance tools. By removing friction from the recipe-to-production pathway, Stone Brewing's team could rapidly prototype new brews and validate process improvements without waiting for engineering schedules.
For details on how Sepasoft's modular approach specifically addresses the limitations of legacy MES systems, listen to the full episode on Listenly, where Tom Heckman walks through the architectural differences that made this type of fast deployment possible.
See also
What are the key benefits of integrating MES directly with HMI and SCADA platforms on a single architecture?
By running modules on Ignition, both HMI SCADA and MES exist on the same platform, enabling simple controls like interlocks without requiring separate systems.
How did modular MES architecture transform the manufacturing software market compared to legacy monolithic systems?
Legacy vendors were selling huge monolithic systems that took years to deliver value and were super complex. Sepasoft's modular approach built from the ground up offers flexibility and faster implementation.