The Indian pharmaceutical industry offers huge opportunities for the automation sector. With globalization and competitive market demands, more and more companies are opening up to digitalization as it is used in many pharmaceutical processes, from drug discovery to manufacturing to packaging. Additionally, compliance with regulatory requirements opens up new opportunities and challenges for automation vendors.
The digital revolution is about creating seamless connectivity between machines, processes and people within and beyond manufacturing facilities to increase quality, productivity and leverage the power of advanced data analytics. data. With these next-generation automation solutions, pharmaceutical manufacturing companies can digitize their operations, increase efficiency, improve product quality, and comply with regulations.
Pharmaceutical companies are typically responsible for reviewing data at every stage of their manufacturing process, from the arrival of raw materials until the final product is packaged and sent for distribution. In traditional pharmaceutical facilities, references and information on drug formulation, production, equipment, and QA-QC data are manually entered into data sheets, which are prone to human error and can even be manipulated. With such delayed information, it is difficult for management to take corrective action and make timely decisions. However, with connected factory and Industrial IoT (IIoT) solutions, manufacturers can access real-time data to monitor production, quality, OEE, and equipment health. It also enables mass customization and batch size with cost effective production.
Improved operational efficiency
With IIoT, manufacturing facilities can monitor shop floor data in real time, improving process efficiency. In the pharmaceutical industry, proper quality assurance is important. Without this, companies cannot guarantee that the product meets the necessary quality and safety standards. Often product quality suffers due to machine downtime. In such cases, monitoring asset conditions in real time can help increase equipment availability, avoiding unplanned downtime.
Monitoring solutions such as Condition Monitoring can predict device failures using real-time data to aid in service planning. Energy monitoring provides us with real-time data on energy consumption and various other vital electrical parameters for a particular machine or process. All of this data is collected from a machine or workshop into the supervision and control system to help us enable maximum utilization of a product’s life cycle, maximizing machine uptime, this which improves the OEE. Management can make faster and smarter business decisions using real-time data of operational insights. IIoT helps prioritize business decisions to reduce operating costs.
B&R condition monitoring modules reliably detect potential maintenance issues and are extremely easy to configure. A unique feature of these modules is that they perform vibration analysis locally. The availability of fully processed results minimizes integration time and cost. These results also provide detailed insight into the mechanics of the system, allowing existing processes to be optimized with maximum efficiency.
B&R’s energy monitoring modules accurately measure all critical electrical parameters as configured. Often it is not only the measured value that is important, but also the exact moment when a group of measured values is read. The module is equipped with a NetTime timestamp function which provides timestamp for recorded position and trigger time with microsecond precision. Later, these values can be analyzed as needed and the energy cost can be optimized, which will lead to an energy-efficient system.
Interconnected machines or processes in the workshop provide a massive amount of important data. B&R’s PharmaEdge solution can easily collect the data. PharmaEdge is B&R’s integrated, out-of-the-box and optimized offering for the pharmaceutical industry to meet the growing demand for FDA compliance. It achieves cybersecurity and advanced features for detailed reporting, analysis and business intelligence. PharmaEdge offers all the benefits of SCADA and a robust control system in a single device. The ability to add energy monitoring, condition-based predictive maintenance, and MES/ERP connectivity results in smart, futuristic machines.
Digital remote access
Indian pharmaceutical OEMs sell their machinery, equipment and systems worldwide. Modern communication helps bring distant places closer together. However, for OEMs, having customers around the world also comes with its own set of new challenges. The situation becomes even more complex during periods of intensive maintenance and unplanned shutdowns. OEMs are increasingly relying on remote maintenance to avoid the expense of traveling service technicians and engineers around the world. Remote maintenance makes connectivity, diagnostics and maintenance easier than ever and improves after-sales service. Service technicians can access machines from anywhere in the world. The secure remote maintenance solution uses the latest IT and security standards and provides significant savings with low capital costs.
B&R’s new remote maintenance solution facilitates and secures the diagnosis and maintenance of machines and equipment. The solution uses the latest IT and security standards, allowing significant savings with a low investment. With B&R’s remote maintenance solution, a service technician can access machines from anywhere in the world to retrieve logbook entries, application data and more. When a customer’s equipment or machine is not working, every minute counts and the pressure on maintenance and production teams is immense to keep the machine up and running. If a service technician isn’t available on site, with B&R’s remote service solution, a technician can log on, diagnose, adjust settings and resolve errors, all in moments.
Enabling mass customization
The demand for individualization creates new business opportunities. However, when performing this operation, a high ratio of setup costs to unit production costs acts as a bottleneck in the manufacturing process. Innovative next-generation mechatronic systems offer key benefits for advanced manufacturing solutions. Flexible, user-friendly conveyors make production more efficient while improving product quality. This makes the production line more economical and efficient at any volume, from mass production to batch size.
B&R’s innovative mechatronic systems, ACOPOStrak, SuperTrak and ACOPOS 6D, make it possible to respond efficiently and effectively to increased demand. These systems can be fully integrated into any machine, reducing the overall line footprint and improving processing accuracy. B&R’s next-generation industrial transport systems can be implemented up to IP69K with protection against dust and water and smooth surfaces that are easy to clean. The hygienic design certifies operation in a food grade environment. Industrial-grade design ensures high uptime and reliability with 24/7 operation. Mechatronic systems synchronize with robotics and CNC systems to create integrated production lines. This helps make production and packaging lines economical and efficient at any volume, from mass production to batch size. These systems allow products to be transported flexibly and autonomously, then grouped together in a station for batch processing. Overall, the production process can be accelerated by up to 50% for a significant increase in productivity. B&R’s intelligent factory motion control in transport technology achieves key benefits: maximum uptime, high-speed transport and positioning, fast changeover and fault-tolerant high quality.
B&R’s innovative mechatronic systems increase overall equipment efficiency (OEE), multiply return on investment (ROI) and accelerate Time To Market (TTM).
The IIoT is currently in its early stages of adoption and has started gaining traction in the Indian pharmaceutical industry, but its eventual impact on the global pharmaceutical sector is indisputable. The IIoT contributes to the standardization of the manufacturing process as well as data integrity. By systematically monitoring and analyzing large volumes of data, manufacturers can benefit from improved production efficiency, productivity, reliability and quality. The IIoT provides manufacturers with a holistic view of production, raw materials, and distribution, which enables better and achievable analysis of processes, thereby increasing operational efficiency.