The Background.

A leading company in the pharmaceutical and serving science sector sought to expand their existing general manufacturing & production facility on site to secure a long-term supply of powdered peptones for their microbiological division. This required the successful design and implementation of a comprehensive Process Control System (PCS) which enhanced overall operational efficiency and control of their on-site manufacturing facility used in microbial diagnostics, biotechnology laboratories and fermentation facilities.

The Client

Our client is a world leader in the Pharmaceutical and Microbiology sector and delivers throughout the bioprocessing market. Their facility supplies products that span clinical diagnostics, food safety, and pharmaceutical manufacturing to a global network of customers via digestion, filtration, evaporation and drying processes.

The Solution.

Overcoming Project & System Challenges
The project faced challenges like ensuring compliance with GMP standards and FDA’s 21 CFR Part 11, prioritising data integrity, and maintaining scalability for future growth. Process optimisation reduced downtime and enhanced operational efficiency, while redundancy features ensured continuous operation and compatibility with existing systems. The project integrated real-time monitoring and analytics for a future-proof solution, achieving a 40% increase in production capacity, reduced downtime, improved maintenance capabilities, and enhanced access to real-time data—all while maintaining compliance with stringent industry standards.

The project delivered a complete Process Control System (PCS), covering everything from panel design and system setup to documentation and testing. We worked closely with stakeholders through workshops to ensure the system met user needs and aligned with existing processes.

The PCS brought together a central Programmable Logic Controller (PLC) and a SCADA system, which helped improve batch management, product quality, and data security. It managed both Master and Control Recipes for up to 50 product variations, with four main recipes expanding into 27 detailed ones. The system also made cleaning more efficient with automated processes, boosting overall plant performance.

The panel setup included a range of components like server cabinets and operator stations, while integrating key hardware such as CPU modules and I/O panels. The software was configured using Siemens PCS7 and WinCC, running on a virtual platform with backup systems for reliability. Testing followed a thorough procedure to make sure the software worked smoothly and met production needs. The commissioning phase ensured that everything complied with industry regulations and fit seamlessly into the client’s existing infrastructure.

The Benefits.

Collaborative approach, delivering a cost-effective and beneficial solution resulting in 40% increase in production capability.

Innovative PCS design using latest Siemens PCS and I/O Hardware and Software solutions.

Design includes scalability/flexibility and provides a 15+ year lifecycle.

Choose UsBack to Case Studies