Pharma Manufacturer Improves Safety and Batch Consistency with a Complete DCS Solution
About the Client
The client is a global pharmaceutical and intermediates manufacturer serving both human
and veterinary health sectors. They provide high-quality custom manufacturing for
customers around the world.
Requirements
The client needed a complete
DCS solution for their manufacturing plant, which operates several hazardous reactors,
including hydrogenation and pilot reactors, as well as ANFD and
utility systems. Another key objective was to follow 21 CFR Part 11 compliance at the SCADA and HMI levels
- Managing multiple reactors and multiple recipes running in campaign-based cycles
- Handling fast recipe changes to meet quick market demands
- Adding safety features due to the hazardous nature of the plant
- Taking responsibility for the selection of field instruments
- Preparing proper documentation for regulatory compliance, including IQ andOQ
The Challenge
The plant had several operational
and
regulatory challenges that needed to be addressed:
These requirements made it essential
to
build a system that was safe, flexible, andcompliant.
The Solution
MIPL provided a fully integrated
PlantPAx-based DCS solution designed for safety, consistency, and regulatory needs. The
scope included:
- Implementing a PlantPAx system with 2,920 I/Os over an Ethernet DLR network for seamless connectivity
- Delivering batching and recipe management aligned with ISA-S88 standards
- Selecting, supplying, and integrating the required field instruments for all process areas
- Enabling automatic batch record generation to meet compliance requirements
- Establishing role-based remote monitoring for both sectional and plant-level visibility
Key Outcomes
Improved Safety
Enhanced safety features were integrated into hydrogen reactors and other
hazardous
operations, reducing risk and improving reliability
Consistent Batch Quality
Standardized recipe and batching controls helped improve batch consistency and
optimize the use of plant assets and utilities.
Single-Point Responsibility
With one integrated package covering DCS and instrumentation, the client had a
smooth project experience and simplified maintenance.
Strategic Outcome
The successful execution of this project
resulted in the client awarding another Greenfield
project, which is currently under
execution.
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.
Safety Integration
Experience in
implementing advanced safety features tailored to the hazardous natureof the
plant,
ensuring compliance and risk mitigation.