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
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Challenge
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Process being Hazardous the system is to be commissioned error/bug free in first trial “RFT”).
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Partially automated systems for independent Process control & equipment’s leading to islands of non-integrated system
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Unable to implement Centralized Recipe based ISA – 88 standard Batch system
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Transformation of existing Manual Batch records to EBMR
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Installation, Line Modifications, trials in running plant so tight shut-down schedules
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Extensive documentation for regulatory compliance (FDS, URS, DQ, IQ, OQ & Performance Qualification)
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Solution
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Rockwell DCS offering Plant-wide Integrated Architecture
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Hazardous (Zone-1) Field mounted remote Intrinsically safe I/O’s
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Intelligent Architecture with enhanced field side diagnostics
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ISA 88 compliant Batch & Recipe Management system
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Enhanced & User friendly recipe system enabling
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Historian, Data base management software & Web based portals for EBMR & Report generation as per regulatory compliances
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Asset Management for securing, managing & tracking of assets
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Validation & documentation services for Regulatory compliance
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Results
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Integrated system resulting in integrated view & control of entire plant from Common Control room
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Consistent Batch quality ensuring high standards of product quality
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Flexibility & Ability to configure and execute multiple Recipes without any changes required in Control program
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Elimination of manual Batch records
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IPR protection of critical information of process / products
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100% error free & easy of operations achieved with Tight control & User friendly Operator interface
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Lower investment on Automation due to Plant-wide Common integrated architecture