Automation and Industrial IT From a Single Source
For the construction of a completely new production facility, our customer needed the perfect mix of automation and IT, both in production and in the office area. Based on our experience in the planning of greenfield projects, we supported the customer with our expertise and a comprehensive offer.
Bacthera was founded at the end of 2019 as a 50:50 joint venture between Chr. Hansen and Lonza with the aim of specifically serving the needs of the emerging living biotherapeutic products (LBPs) industry. LBPs are a new class of drugs that contain living microorganisms to treat or prevent various diseases.
In order to expand its CDMO services, Bacthera has built a new production facility in Visp (VS, CH). The building has seven floors, of which the lowest three are currently used for production, the laboratory, utilities and offices. In future, all floors will be managed.
A reliable IT/OT infrastructure is an essential component for efficient and safe production. As an experienced provider of IT/OT infrastructure and production DCS (Distributed Control System), we were mandated with the planning and commissioning of the necessary systems.
Reliable IT system landscape
Thanks to our experience from other projects, we were able to determine the requirements at an early stage and identify the right solutions for the office IT infrastructure.
All areas of the production building were to be equipped with wireless connectivity. To this end, CTE planned and configured approximately 110 Access PointsWhat are access points?Access points connect mobile devices to the network. Using multiple access points extends the range and ensures reliable Wi-Fi coverage, even in large buildings. and put them into operation. In addition, on the three floors IT SocketsWhat are IT sockets?IT sockets are endpoints of network connections. They enable data exchange, with ports routing traffic precisely to the correct application. provided to ensure continued productive work in the future. The entire network is based on Cisco componentsWhat is Cisco?CISCO is a provider of networking and IT components that ensure secure, stable, and reliable operation even under heavy load., which are known for their reliability and performance.
A redundant virtualization cluster was set up as the server platform, on which various virtual machines (VMs) for the domain, file server, or RTDS (Real-Time Data Services) are provided with high availability. The RTDS enable real-time monitoring and control of production processes. The Server nodesWhat are server nodes?Server nodes are server units within a network that collectively provide computing power or services. They distribute tasks efficiently to improve availability and reliability. are also operated on two different floors to enhance reliability.
Qualified industrial IT in the GMP environment
As a highly regulated sector, the pharmaceutical industry is subject to strict GMP guidelines. Accordingly, the IT infrastructure in the industrial environment (OT) is also subject to strict quality standards. As a result, servers and networks also had to be qualified.
In general, the OT server and network architecture was set up in the same way as the IT infrastructure. In addition to file servers and domains, the OT server also included Jump hostsWhat do we mean by "jump hosts"?Jump hosts are secure access servers used for remote maintenance of internal systems. They verify and log remote access attempts (e.g., via VPN and MFA) to protect critical infrastructure. has been implemented, enabling package unit suppliers to remotely access their machines. This increases the efficiency and flexibility of maintenance work. In the production area, the integration of approximately 14 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. planned and coordinated from various suppliers and integrated them into the OT SystemWhat do we mean by OT systems?By OT systems, we mean everything that enables the day-to-day operation of a facility: from control and management systems to user interfaces, OT networks, and data connectivity. carried out.
DCS (Distributed Control System)
A DCS is a system for controlling and monitoring production processes. Based on an evaluation supported by CTE, Bacthera selected Zenon from COPA-DATA. This system, in combination with Soft-Logic, offers a high degree of flexibility and scalability while requiring relatively little hardware and installation effort. The field-based remote I/Os were connected to the Soft-Logic system via Profinet. The Zenon services themselves (SCADA and Logic) run redundantly on different hosts, and visualization was implemented via terminal sessions on Thin clientsWhat is a thin client?A thin client is a computer with minimal hardware. Data processing is handled centrally on a server, which reduces maintenance, costs, and energy consumption while optimizing space utilization and efficiency. implemented.
The DCS was mainly used to monitor and alarm GMP equipment such as freezers or refrigerators. These devices are important for storing the LBPs under optimum temperature conditions. In addition, we have implemented pure water production, communication to various package units and communication to the building via the DCS. All critical alarms are also escalated via SMS service. This ensures a rapid response in the event of a problem.
Conclusion
Our customer Bacthera, and ourselves, are delighted with the result achieved together. We would like to take this opportunity to thank them once again for the trust they have placed in us in order to implement all three complex disciplines of automation, OT and IT in one innovative project. We look forward to continuing our successful collaboration with Bacthera.
