Retrofit of a granulate mixing system at Acino Pharma
What can be done to reduce the increasing maintenance downtime of production facilities? Our customer Acino Pharma commissioned us to find an efficient solution for an aging active ingredient mixer and at the same time to increase its production capacity. The zenon Batch Control from COPA-DATA was used.
The Swiss pharmaceutical company Acino Pharma produces medicines at its site in Liesberg. In order to increase machine availability and minimise downtime, the production systems in use are checked regularly.
As a result, CTE received the order to retrofit an active ingredient mixer. Our analysis showed that, in addition to the PC operator stations, the frequency converters in the system also needed to be replaced. With the replacement of the PC operator stations and their visualisation, it quickly became clear that we would rely on our proven CTE basic function concept for this project.
The zenon software platform from COPADATA in the current version V11 was to be used as the appropriate visualisation. With our CTE Automated Engineering and the Out of the Box functions, this is the perfect choice to ensure efficient, fast and high-quality work.
The SE version of zenon Batch was used for the existing system type. The connection with our qualified CTE GFK head in the newly programmed PLC makes this an advantageous element in the future production plant.
FAT with WinMOD
In collaboration with the operator, all of the system’s functions were recorded and documented in the new functional specification. As part of this process, improvements and optimizations related to system operation and process flows were also proposed and incorporated into the FS.What is a Functional Specification (FS)?A document that describes the functional requirements of a system.
Following the successful customer review of the new functional specification, the green light was given to begin developing the PLC. What is a PLC?A PLC (Programmable Logic Controller) is a system for process control. It collects sensor data via inputs, processes it, and controls actuators such as motors or valves via outputs. program and the zenon visualization. During the subsequent software FAT, what does FAT stand for?The FAT (Factory Acceptance Test) is a simulation test conducted at the manufacturer’s site to ensure that the system functions properly before delivery to the customer. all functions were thoroughly tested with the plant operator. For the FAT , the entire system was simulated using WinMOD. This allowed operator training to be conducted on the test system following the successful software FAT.
Zenon in action
As is always the case when retrofitting a production facility, downtime should be kept to a minimum. To ensure that production could resume on schedule two weeks after the retrofit, production-ready recipes were created and tested in collaboration with the customer immediately following the FAT. A significant time-saving advantage also resulted from the fact that we had already commissioned zenon Batch in its original version 7.11 on various systems at the customer’s site. The software platform with the CTE basic functions concept is well-known and appreciated by production staff. After the smooth installation of the new peripherals (Stahl Remote HMI for EX Zone2—What are EX zones?Areas with explosive atmospheres. Depending on the risk and duration of this hazard, they are classified to prescribe appropriate protective measures and permitted equipment.) and loading the software, the line test began. After a brief functional test of the software, the two frequency converters were also successfully replaced with two new SEW Movitrac units. After about two days of conversion work, we began our functional tests on the system.
FAT as a guarantee of success
Thanks to the successful completion of the FAT at the office, the SAT—what does SAT stand for?The SAT (Site Acceptance Test) is an on-site test conducted at the customer’s location to ensure that the system functions properly under operating conditions after installation— was completed in just two days . The subsequent cleaning of the system was carried out directly according to the CIP procedure that had been established earlier .What does CIP stand for?CIP (Cleaning in Place) is an automatic cleaning method for process equipment such as tanks, performed directly on site without the need to disassemble them.
The system was successfully handed over to production on completion of the training for employees at the "Production, maintenance and management" level.
