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 picture shows a mixer for active ingredients by Acino Pharma. — Turning old into new: we have brought this active ingredient mixer up to date for Acino.

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.

CTE Assignment

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 FS recorded.

Following the successful customer review of the new functional specification, the green light was given to begin drafting the PLC program and the zenon visualization. During the subsequent software FAT 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 2) 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 SAT was completed after just two days. The subsequent cleaning of the system was carried out directly using the CIP Recipe completed.

The system was successfully handed over to production on completion of the training for employees at the "Production, maintenance and management" level.

Retrofit of a granulate mixing system at Acino Pharma

CTE Assignment

FAT with WinMOD

Zenon in action

FAT as a guarantee of success

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