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 workflows were also proposed and incorporated into the FSWhat is a functional specification (FS)?A document that describes the functional requirements of a system. recorded.
Following the successful customer review of the new functional specification, the green light was given to begin drafting the PLCWhat is a PLC?A PLC (programmable logic controller) is a system used 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 FATWhat does FAT stand for?The FAT (Factory Acceptance Test) is a simulation test conducted at the manufacturer's facility to ensure that the system is functioning properly before it is shipped to the customer. All functions were thoroughly tested with the plant operator. For the FAT, the entire system was simulated using WinMOD. This made it possible to conduct operator training 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 following the FAT. We also gained a significant time advantage because 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. Following the smooth installation of the new peripherals (Stahl Remote HMI for EX Zone 2What are EX zones?Areas with explosive atmospheres. These areas are classified based on the risk and duration of the hazard in order to specify appropriate protective measures and permitted equipment.) and the installation of 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 SATWhat 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 after just two days. The subsequent cleaning of the system was carried out directly using the CIPWhat does CIP stand for?CIP (Cleaning in Place) is an automated cleaning method for process equipment, such as tanks, that is performed on-site without the need to disassemble the equipment. Recipe completed.
The system was successfully handed over to production on completion of the training for employees at the "Production, maintenance and management" level.
