industrial automation specialist and system integrator who can provide key support in identifying and implementing the most effective improvement strategies for the intended control system .
A full-service provider , such as Optimal , should be preferred , as it can streamline the entire project as well as provide assistance at any stage while enabling continuous improvements . Furthermore , such a partner can help reverse engineer existing setups or handle situations when supporting documentation may be limited , ensuring that the new setup can run smoothly .
With nearly 40 years of experience in industrial automation and control technology applications in the chemical and ( bio ) pharmaceutical sector , Optimal has long track record of supporting the successful upgrade of FBDs . These have enabled end users to advance their operations and drive their competitiveness in increasingly demanding markets .
Case study : customised control system enhancement bolsters productivity
In a bid to modernise its FBD operations , a prominent pharmaceutical manufacturer sought to move beyond the limitations of its legacy control setup , which was reliant on traditional push-button controls that only supported basic functions . Optimal stepped in to upgrade the control system ’ s capabilities by introducing a PLC-driven solution .
This overhaul integrated a more advanced control system and key visualisation platforms , such as human-machine interfaces ( HMIs ) and supervisory control and data acquisition ( SCADA ) software . This provided both a more sophisticated control mechanism and enabled precise material tracking and tracing . The implementation of a comprehensive monitoring solution helped the pharmaceutical company manage feedstock across the entire manufacturing journey , from raw material to the final product .
Offering a highly efficient drying method , FBDs play a fundamental role in various manufacturing industries , including pharmaceutical , chemical , and food & beverage .
Traceability was complemented by real-time batch reporting , which offered invaluable documentation for quality audits . By optimising batching processes and dispensary controls , Optimal was able to deliver a seamlessly integrated and autonomous solution that drove a remarkable 50 % increase in productivity for the FBD . This surge in efficiency not only resulted in a swift return on investment but also positioned the pharmaceutical giant at the forefront of cuttingedge manufacturing .
Case study : Digitalising FBD operations
Faced with the need to refine its FBD operations to enhance product consistency and reduce processing times , a leading pharmaceutical manufacturer asked its preferred automation and system integration expert , Optimal , to develop a suitable control system . As an expert Process Analytical Technology ( PAT ) implementation specialist , Optimal suggested the use of this framework as part of a more advanced process control system . This would support real-time moisture monitoring through in-line near-infrared ( NIR ) spectroscopy that , coupled with data from existing sensors , could form the basis of a robust multivariate analysis ( MVA ) model .
Thanks to this solution , the company gained unprecedented insight into the drying phases , facilitating informed decisionmaking for operators and subject matter experts . The result was a more thorough understanding of the process , leading to improved cycle times , heightened product quality and a substantial boost in profitability . The control system , which leveraged the award-winning PAT knowledge platform synTQ , enabled on-thefly temperature adjustments to optimise end product quality and processing times . Harnessing PAT futureproofed the system and opened avenues for scalability as well as further optimisation in other areas of the manufacturing process .
Case study : Advanced transparency supports regulatory compliance
When a premier OSD form manufacturer wanted to improve the transparency , accessibility and integrity of its FBD process as well as product data , Optimal implemented a secure and regulatory-compliant solution for data sharing and storage . The existing system ’ s capabilities included reliable data capture and storage within a cutting-edge SCADA platform .
To enhance accessibility and regulatory compliance , an Information Technology Company ( ITC ) -managed data centre was established , enabling direct , seamless data reception and visualisation by the Medicines and Healthcare products Regulatory Agency ( MHRA ). The pharmaceutical producer ’ s adherence to cGMP guidelines was significantly strengthened , leading to the expansion of the framework to additional production units .
For further information , please visit www . optimal-ltd . co . uk
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