In continuous manufacturing, whether metals, pharmaceuticals, material handling, or otherwise, distributed control systems are the go-to. DCSs handle complicated, multi-component automated processes via an intricate communication network that allows the user to monitor plant-wide activity in real time.

In continuous manufacturing, whether metals, pharmaceuticals, material handling, or otherwise, distributed control systems are the go-to. DCSs handle complicated, multi-component automated processes via an intricate communication network that allows the user to monitor plant-wide activity in real time.

Among the most effective and comprehensive DSCs is Emerson’s DeltaV line of control system software. It offers manufacturers the possibility of wireless plant-wide automation. Predictive model control, neural network control and cyber-secure architecture are just a few of the features of this cutting-edge software. Implementing DeltaV automation technology can maximize your production potential while enhancing safety and reliability.

The Specs on Emerson’s DeltaV Product Line

DeltaV wireless plant network solutions require less investment of time, cost and resources than a wired system, and can be tailored to the exact needs of the client. Some features of DeltaV’s robust design include:

• Scalability: Implementing a wireless control system doesn’t have to be an all-or-nothing effort. DeltaV applications can be added in stages elegantly without need for recontrol.
• Reliability: DeltaV DSCs are designed with redundant encryption and authorization measures built into mesh networks that ensure end-to-end security. This includes plant-wide via firewall protection, security testing, regular updates, and regulation-compliant software.
• Intuitive Networks: DeltaV networks self-organize and self-heal. Intelligent mesh design chooses the most efficient route to the wired network while mitigating interference. It can also pivot to a new path when interference does occur.
• User-Friendly Controls: DeltaV’s salient interface is easy-to-use, as it simplifies configuration, maintenance and operations.
• Advanced, Flexible Capabilities: This software is highly-versatile, allowing adaptable customization for specific manufacturing needs. Advanced control capabilities include fuzzy logic control, neural network control and predictive model control.
• Cross-System Compatible: DeltaV DSCs can be integrated with other control systems such as MES and plant historians, which allows automation system integrators to design elegant, comprehensive plant-wide control solutions.

Advantages of Implementing a Distributed Control System

A distributed control system (DCS) is a computer-based industrial control system that is used to monitor and control complex industrial processes. They’re typically comprised of a network of computers and controllers that are distributed throughout the industrial process.

The computers and controllers communicate with each other using a high-speed communication network. This allows the DCS to collect data from sensors and send control signals to actuators throughout the process. DCSs are typically used to control large and complex industrial processes, such as those in oil refineries, power plants, and chemical plants because they can be used to control a wide range of variables, such as temperature, pressure, flow, and level.

Why consider a DCS like Emerson’s DeltaV for your facility’s operation? For some companies’ operations, they offer advantages over a centralized control system:

• Reliability: DCSs are more reliable than centralized control systems because they are distributed throughout the process. If one component of a DCS fails, the other components can continue to operate.
• Scalability: DCSs are more scalable than centralized control systems because they can be easily expanded to control larger and more complex processes.
• Security: DCSs are more secure than centralized control systems because they are more difficult to hack.
• Flexibility and adaptability: DCSs are more adaptable than centralized control systems because they can be easily reprogrammed to control new processes or to change the way that existing processes are controlled.

The automation company you partner with is key to (a) knowing whether a DCS is the right automation solution for your facility and (b) implementing a DCS that is well-integrated throughout your facility.

E Tech Group: Strategic, Comprehensive Factory Automation

Emerson is just one of the top-tier brands in E Tech Group’s extensive portfolio of control system expertise. Our automation engineers work with industrial manufacturing, data center and mission critical clients across North America, designing and implementing strategically-integrated control systems with the best automation products available.

We are a CSIA-certified integrator offering industry best practices in automation fields such as quality development, information systems management, cyber security, system development lifecycle, and more. With a focus on adding value that future-proofs your automated processes, E Tech Group constructs secure, user-friendly, integrated automation solutions across industries.

Robotics systems have been a part of the pharmaceutical industry for nearly half a century to manage the mass processes of sampling and testing drug candidates, and those drugs ready for distribution into the healthcare system. Fast forward to today, and automation technology is so common within the pharmaceutical industry it now bleeds over into patient testing and research, commercial pharmacy procedures, patient medication administration, and more.

With the enormous pressure on the pharmaceutical industry to continue to discover and develop new drugs, competition is now an endemic part of healthcare research. Automating repetitive processes like counting, batching, sorting, and packaging allows a much higher throughput while eliminating human error. Higher processing capacity coupled with well-documented and validated data are values now at the forefront of pharmaceutical logistics, especially since COVID.

The 2020 pandemic and the ensuing explosion of the e-commerce market changed how the entire healthcare industry worked, and industrial medicine was no different. Previously, the field was primarily B2B-driven. But with patient convenience and access taking center stage, automation has gone from beneficial to vital for pharmaceutical entities.

A recent survey of IT buyers by Bain revealed that, post-COVID, 80% of companies have or are planning to up their automation capabilities, but that less than half of them will likely meet their productivity goals, which is why the automation and control system company they use needs to understand the dynamic nature of the medical field, and all the factors involved in an integrated robotics system.

Understanding a Pharmaceutical Facility’s Automation Needs

Amongst the production needs of drug manufacturers and medical research facilities include:

(1) the ability to rule out potential drug candidates quickly and effectively while remaining FDA-compliant

(2) surety that their IT system is secure enough that their intellectual property won’t be compromised

(3) that the data these automated systems put out is easily monitored, read and analyzed.

FDA requirements are extremely stringent in the medical field. The drug development process requires several assays to be tested before moving a new medicine to human trials. Automation streamlines these processes:

• Removing the need to manually test a drug’s absorption, distribution, metabolism, and excretion rates speeds the elimination process exponentially.
• Streamlining strict clean room procedures and integrating the robotics equipment with a comprehensive monitoring system improves the sanitizing process by keeping the clean room consistent and reducing the human labor needed.
• Integrated control systems gather, record and allow real-time user access to all the automated systems in a medical facility, eliminating holes and mistakes in documentation and validation processes.

IT design is an integral piece of pharmaceutical automation systems. Medical manufacturers, whether it’s vaccines, medications or devices, need all-encompassing cybersecurity to protect the integrity of their processes/products as well as other proprietary assets like recipes, research notes and trial data. IT systems need to be as flexible as they are impenetrable so that the facility remains secure even as their robotics systems continue to develop and scale.

A pharmaceutical company automating their processes also requires robust information management systems. In medicine, there are complex relationships between different sets of data; researchers and engineers need a control system that allows for a wide-angle view of various sets of data to accommodate for the intricacies of analysis.

Integrated controls for automated equipment offers safety monitoring, remote access, rapid discovery and response to compliance problems, and proactive operational maintenance. Pharmaceutical automation companies can create integrated systems that allow users to analyze operations in precise, readable ways. E Tech Group engineers utilize the latest in automation software when designing a building’s robotics and control systems.

Staying Ahead of the Production Curve with Flexible Robotics

Digital automation technology is developing as rapidly as pharmaceutical manufacturing, which means that the applications of robotics and AI in industrial and commercial pharmaceuticals have proliferated. In addition to benefits associated with processes, pharmaceutical automation can be applied in a number of other operations.

With regard to pharmaceutical logistics, automation can simplify administrative operations:

• Finance: accounts payable/receivable, payroll, tax processes, reporting, bank and intercompany payments/receipts, expense analysis and reporting
• HR: time records and validation, master employee data management, expense management, compliance tracking and training.
• IT: help desk and testing management, server and security monitoring
• Planning: data analytics and management, inventory management and demand forecasting, procurement data management, supplier and contractor management

With regard to the process of developing, producing and distributing a drug, automation reduces or eliminates the need for human labor in:

• Dosing (granule, powder, liquid)
• Packaging (sorting, counting, filling, bottling)
• Processing systems (granulation, blending, extrusion, etc)
• Tablet manufacturing (compression, encapsulation, coating, etc)
• Traceability (product tracking, RFID labeling, quality management, etc)

Many of these repetitive tasks are completed in conveyor and sorting equipment which, when automated, amplify throughput in transferring, inspection, grouping, and rejection – all key aspects of keeping a tight leash on quality control for outgoing products.

As drug trials, developments and approvals expand, so, too, will medical manufacturers need to expand their capabilities. They’ll need to produce more, and they’ll need to be able to produce an increasing number of different products. This will require adaptable robots and intuitive control systems that optimize a facility’s ability to outrun growing competition without compromising the quality of their laboratory and manufacturing processes.

Our automation partners at Rockwell and Siemen’s offer automation software specifically designed for the needs of the pharmaceutical industry. Rockwell’s PharmaSuite® MES offers end-to-end coverage for a facility’s processes with a design focused on efficiency and scalability. In the same vein, Siemen’s SIMATIC SIPAT PAT allows for continuous manufacturing, increasing output by 30% and reducing operational costs by 10-20%.

Benefits of Automating Pharmaceutical Facilities

The advantages of automating a medical production facility cannot be understated. Every type of pharmaceutical entity – from a drug giant to a small medical device startup – can harness the power of robotics automation to improve their operations. Benefits of building-wide automation include:

• Accuracy: There is no performance curve for things like mixing, stirring, tableting, weighing, etc. Automation eliminates human error and subsequently product defects.
• Sterility: Less human contact with the pharmaceutical components leads to less contamination.
• Efficiency: Automation speeds production and can allow a facility to transition to continuous processing.
• Visibility: An integrated control system gives transparent access to data, allowing problems to be identified and remedied quickly.
• Analytics: Access to data and user-friendly HMIs allow for data analytics that can inform on inefficiencies in processes workflow, etc, as well as help plan for and predict changes.
• ROI: An automated pharmaceutical facility will see energy costs fall, waste reduced, throughput increased, quality improved, and need for labor reduced.

Challenges the Pharmaceutical Industry Faces with Automation

Implementing building automation at a pharmaceutical facility affects more than production quality and throughput. And biology and chemistry are vastly complex fields of science; not every process is as easily automated as another.

The pharmaceutical industry and the companies designing their automated systems will face growing pains they’ll need to face collaboratively. Just as in any clinical trial, all the variables will have to be managed properly in order for a medical entity to achieve its quality and productivity goals:

• Automated processes will need to be scalable.
• Automation technology will need to encompass increasingly more complex processes.
• Pharmaceutical companies will need to reorganize job structure to compensate for labor shortages and transition employees to different positions.
• Robotics will need to increase the learning capabilities of its software.
• Subjective analysis of skilled human labor will need to work with the objective analyses of AI.
• Systems will need to be adaptable to accommodate both new treatments and novel applications of existing treatments.

Futureproof Your Pharmaceutical Facility with Scalable Automation

Healthcare research and production facilities require flexible, scalable automation solutions to keep up the rapid process of drug sampling, testing, counting, and manufacturing. E Tech Group’s extensive experience in industrial life sciences allows us to offer pharmaceutical clients leading-edge automation integration and control system design that keeps them competitive and cost-efficient.

The benefits that state-of-the-art facility automation has to offer pharmaceutical companies make robotic systems a must for a medical products manufacturer to successfully pivot in this evermore consumer-driven field. When it comes to the field of industrial medicine, change is a constant reality. And as digital technology continues to improve, so, too, will our ability to create, produce and distributed life-changing medications and life-saving treatments to consumers.

E Tech Group is a nationwide pharmaceutical automation company with capabilities across a wide variety of life science fields, including emerging biotechnologies. We design and implement robust, adaptable control and IT systems that keep your documentation thorough and your processes validated, so you can stay at the forefront of drug research and development.