Automation of production lines for pharmaceutical companies
Package units can be used to assemble a production system according to the plug-and-play principle. ControlTech Engineering was commissioned to connect a new package unit to the existing DeltaV building management system. It was actually quite simple, but we had to dig deep into our bag of tricks to define the right procedure.
For an international pharmaceutical company, our experts automated a production line while also ensuring the integration of the Package UnitsWhat are package units?Package Units are pre-assembled, tested functional units designed for various industries. They simplify processes, reduce installation time, and enable quick plug-and-play commissioning. to the building management system. The package units had already been defined; CTE was responsible for describing the interfaces and implementing the system.
In principle, this approach poses no problems. CTE simply needs to connect several new package units to the existing DeltaV building management system (BMS). The systems should be configured in accordance with the customer’s specifications using the communication protocol OPC UAWhat is OPC UA?Open Platform Communications Unified Architecture is an industrial communication protocol that enables the secure exchange of data between machines, as well as between machines and computers. be connected. Since the original version of the building management system was not yet capable of communicating via OPC UA, an upgrade had to be performed. A two-week window was available, but unfortunately, the upgrade could not be carried out. Due to time constraints and uncertainty, an alternative solution had to be found quickly in order to connect the new package units to the existing building management system.
Routine becomes emergency
What started as a simple connection to the package units turned into an emergency. Innovative solutions had to be found quickly, or the project would have been at risk of delays. Working with the customer, we came up with the idea of using a Kepware server to implement the OPC UA communication protocol in OPC DAWhat is OPC DA?Open Platform Communications Data Access is an older protocol for real-time data exchange between machines and Windows-based computers. to convert. An additional server was required for the implementation. But those lead times were too long given the urgency of the situation. The project team had to find other options quickly. CTE didn’t hesitate and made one of its servers available. As a stopgap measure to ensure the system would function 100% at all times. But that’s not a long-term solution. It is undesirable to have an additional server in the system. It could fail and interrupt communication—a situation that must be prevented at all costs. The conclusion is therefore mixed: While the final solution works, it still needs to be optimized as soon as possible. Even though our experts made the best of the emergency situation and the system is up and running.
Solution-oriented to the goal
This example shows how pragmatic and solution-oriented CTE's approach is. As an owner-managed company, CTE stands for commitment and partnership at all times. These are not just empty words, they are genuine corporate values. Even if the emergency solution appears risky, the specialists at CTE have found a way to prevent the worst-case scenario. The initial situation was nothing out of the ordinary. But the emergency solution required flexibility and quick decision-making processes. Thanks to its organizational structure, CTE has flat hierarchies and employees can really make a difference. That's why our customer is also satisfied: "We would order from CTE again at any time. The employees are reliable and work to a high standard. The close cooperation and exchange were very helpful."
