Success Stories
SIP / CIP Unit
Business Case: One of the Pharmaceutical Injection Plant
The project aimed to develop an automation solution for Sterilization-In-Place (SIP) and Clean-in-Place (CIP) vessels.
Systems and Tools:
– Siemens PLC
– Zenon SCADA
– VFD on Modbus communication
Project Scope:
– Develop System Design: System FDS, FAT Protocols, Test Instructions, and Cases
– Software Development: Entire control module through PLC programming and SCADA Screens
– Control System Validation: Adhering to GAMP guidelines
– Internal Testing and Factory Acceptance Test: Conforming to customer FAT protocols
– Extended Commissioning and 24×7 Support Missioning Support
EMS / BMS
Business Case: Environmental monitoring system(EMS) in one of the pharmaceutical plant
The project was to install continuous monitoring system for T/rH and DP in various Grade of clean room.
Systems and Tools:
– Zenon SCADA
– Clean room Displays and relevant sensors
– Networking
– DDC
– Server and Clients
Project Scope:
– Design and selection of instruments as per requirement.
– Provide redundancy of data on devise and SCADA level.
– Complete installation and commissioning.
– Development and designing of screens ,reports ,alarms and audit trial.
– Validation and Qualification as per 21CFR 11 and EU annex 1.
Environmental Monitoing system(EMS)/ Building Management system(BMS)
Business Case: Utility and cold room monitoring system for one of our customer.
Various operations of heat exchanger, Chilled Water Systems , Air Compressor, Water system and Cold room of plants to be monitored centralized.
Systems and Tools:
– Zenon Energy SCADA
– Modbus and BACNET protocol
– Fiber optic and ethernet based networking
– Server and Clients
Project Scope:
– Co-ordinate with client for Project Inputs.
– PLC Program development as per the provided FDS
– Modbus and BACNET Communication with third Party devices
– Scada development based on P&ID, Dashboard, reports and trending requirements.
– Pre-commissioning of system
– Onsite commissioning of the system.
– Drive Communication and testing, Safety Checks
Utility Management system(UMS)
Business Case: Injection line automation for OEM.
This includes replacing the existing outdated PLC and HMI system with a new system that includes a washing tunnel and filling machine.
Systems and Tools:
– Siemens TIA Portal
– Rockwell/Allen Bradley Compact Logix PLC
– Siemens SCADA
Project Scope:
– Replace the existing PLC and HMI system.
– Install a new PLC and SCADA system.
– Develop PLC and SCADA logic as per OEM requirements.
– Design and wire the new system according to the
requirements.Design and wire the new system according to the requirements.
– Test and commission the system onsite.
Pharma Formulation Tablet plant Automation
Business Case: Updating and automating the Formulation tablet plant’s Coating, RMG, and FBD Equipment.
To upgrade the existing Coating, RMG, and FBD machines with IPC and SCADA-based systems to comply with 21 CFR 11 requirements.
Systems and Tools:
– Siemens SCADA
– SQL database
– IPC
Project Scope:
– Study the existing system and install IPC-based SCADA software in place of the existing HMI.
– Modify and improve the existing PLC.
– Develop a SCADA application based on customer requirements and in accordance with 21 CFR Part 11 compliance.
– Conduct offline development and onsite commissioning of the system.
– Qualify the system (IQ, OQ) and generate a CSV report.
LAF Monitoring System
Business Case: Grade A and Grade B area LAF monitoring system for one of our injectable formulation plant customer.
24X7 monitoring of LAF DP and its running status with action and alert and audio visio alarm functionality in clean rooms.
Systems and Tools:
– Siemens SCADA
– S7-1200 PLC take all analog values on SCADA
Project Scope:
– To communicate with existing DP transmitter and installed new DPT wherever required.
– Installation and cabling of network cable and sensors and alarm filled wiring.
– Development of SCADA application based on customer URS and as per 21CFR part 11 compliance.
– Offline development and onsite commissioning of system
– Qualification(IQ,OQ) and CSV.
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