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Common integrated plant-wide system for solvent transfer, reactor process & utility controls, end of line equipment & EBR for bulk drug plant

Major Bulk Drug manufacturer implements Complete Solvent transfer, Reactors & End of line equipment Automation, Electronic Batch Monitoring & Recording system for tight process control, high availability, consistent product quality & compliance to regulatory requirements.

Challenge

Process being Hazardous the system is to be commissioned error/bug free in first trial "RFT").
Partially automated systems for independent Process control & equipment's leading to islands of non-integrated system
Unable to implement Centralized Recipe based ISA – 88 standard Batch system
Transformation of existing Manual Batch records to EBMR
Installation, Line Modifications, trials in running plant so tight shut-down schedules
Extensive documentation for regulatory compliance (FDS, URS, DQ, IQ, OQ & Performance Qualification)

Solution

Rockwell DCS offering Plant-wide Integrated Architecture
Hazardous (Zone-1) Field mounted remote Intrinsically safe I/O's
Intelligent Architecture with enhanced field side diagnostics
ISA 88 compliant Batch & Recipe Management system
Enhanced & User friendly recipe system enabling
Historian, Data base management software & Web based portals for EBMR & Report generation as per regulatory compliances
Asset Management for securing, managing & tracking of assets
Validation & documentation services for Regulatory compliance

Result

Integrated system resulting in integrated view & control of entire plant from Common Control room
Consistent Batch quality ensuring high standards of product quality
Flexibility & Ability to configure and execute multiple Recipes without any changes required in Control program
Elimination of manual Batch records
IPR protection of critical information of process / products
100% error free & easy of operations achieved with Tight control & User friendly Operator interface
Lower investment on Automation due to Plant-wide Common integrated architecture

Common integrated plant-wide system for solvent transfer, reactor process & utility controls, end of line ...

Common integrated plant-wide system for solvent transfer, reactor process & utility controls, end of line equipment & EBR for bulk drug plant

Challenge

Solution

Result

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