Life Science Manufacturer Improved Batch Quality and Reduced Downtime with Advanced DCS System
About the Client
The client is a leading life science company established in 1993 and expanded further in
2015. They manufacture a wide range of agrochemicals and pharmaceutical intermediates.
Requirements
The
client wanted a new control system that could:
• Ensure safety, smooth
operations, and consistent quality
• Match the production
capacity of their existing plant
• Integrate smoothly with
their current technologies
• Support future
digitalization
• Deliver a complete DCS
solution aligned with market demand
- Handle multiple unit operations, including reactors and distillation
- Support multi-recipe batch production
- Improve operator efficiency and visibility
- Manage alarms effectively as per industry guidelines
- Maintain high safety standards across the plant
The Challenge
The client needed a modern
automation setup that could:
All of this had to be delivered while
preparing the plant for future digital
growth.
The Solution
MIPL supplied and implemented a
comprehensive DCS solution designed to meet the plant’s operational and safety needs.
The team delivered:
- Redundant 1756-L74/L75 processors and 1794 I/Os supporting 2000+ points
- Automation strategies and specifications for key operations such as reactors, distillation units, ATFDs, and Centrifuges.
- An ISA-compliant PlantPAx system with High-Performance HMI and an integrated Safety Management System
- A multi-recipe batch solution using RA toolkit and an ISA S88-compliant Sequence Manager
- Alarm management implemented as per required standards
- A digital BMR system with safe tablets to improve operator efficiency and safety
Key Outcomes
Faster Changeovers, Less Downtime
Improved automation and batch handling helped reduce changeover time and
minimize production interruptions.
Consistent Quality with Every Batch
Standardized batch records and better process visibility supported continuous
quality control and quick corrective action.
Cost Reduction and Business Growth
Better throughput and consistent quality helped reduce overall costs and
improved customer confidence.
Strategic Outcome
With the project delivered on time and as planned, the client awarded MIPL new
digitalization projects for additional plant areas.
Why the Client Chose MIPL
Proven Experience
Over 30 years
of experience in automation and control systems with a strong track record of
successful projects.
Tailored Solutions
We design
automation strategies tailored to your specific needs, not one-size-fits-all
approaches.
Quality & Innovation
We're
committed to high standards, safety compliance, and using the latest
technologies to deliver results.