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Sustainable and efficient – production systems in brownfield sites
Fully digitalized and at the same time reliable with time savings of 60% during engineering and implementation.
The Serum Institute of India in Pune is one of the world’s largest vaccine manufacturers. Around 1.5 billion vaccine doses are produced there every year and sold worldwide.
It was founded in 1966 by Dr. Cyrus Poonawalla with the aim of producing lifesaving immunobiological preparations that were previously in short supply in India and imported at high prices.
The challenge
Digitalization and improving sustainability
Sustainability and digitalization are essential at a brownfield site. The focus is on optimizing consumption in factories and reducing the carbon footprint of existing facilities or new installations. In this context and in addition to the challenges it presents, digitalization also offers opportunities to increase efficiency and competitiveness. Digitalization is the key to sustainable production based on data. The data is collected and evaluated. As a result, maximum possible transparency is achieved regarding consumption and processes. This information can be used to develop measures to minimize consumption and optimize processes.
The first step involves capturing, storing, and visualizing more than 300 machines and processes for connection to the SCADA system. This is how the data is obtained. The large number of different communication protocols and the connection of OT with IT posed a challenge for the project. The Data Collection Box enabled the desired data to be acquired from the existing systems without jeopardizing certifications or ongoing operation.
The solution
The openness of PLCnext Technology makes it easy to connect OT and IT securely and to operate various interfaces. Now, we are able to not only produce more efficiently and therefore more sustainably, but also protect our IP.
In order to meet promised vaccine deliveries and avoid expensive, resource-intensive downtimes, it is important to avoid system failures under all circumstances. Process transparency and anomaly detection help to detect and eliminate emerging defects, for example, due to material fatigue, before they even occur.
The complete transparency of processes and consumption also serves as the key to greater sustainability, since the company now also has a better focus on resource efficiency through data transparency and can therefore make optimizations in line with the sustainability balance sheet.
This ensures consistent quality, high process efficiency, and the conservation of valuable resources.
In addition to data acquisition and processing, we were able to win over the customer with our extensive cybersecurity expertise and certification in accordance with IEC 62443. Here at the Serum Institute of India, we have achieved Security Level 2, which was extremely important for the pharmaceuticals company in order to protect formulations and vaccine production processes against unauthorized access, for example.
Your advantages
Productivity boost by collecting, storing, and visualizing process data
Optimization through the use of artificial intelligence and machine learning
Improving sustainability with the help of data transparency
360° cybersecurity in accordance with IEC 62443
60% reduction in engineering time with the preconfigured Data Collection Box solution
Feel free to contact us. We will consult with you to find the ideal solution together.
Summary
Unlimited data exchange with open interfaces
A major advantage in this project was the openness of our PLCnext Technology. This enabled the operation of the many different interfaces and would not have been possible with a proprietary system. As an open and scalable interface, the IIoT framework standardizes the very different types of data. It enables it to be translated for the customer’s existing SCADA system, thus connecting OT and IT. In addition to data acquisition and processing, we were able to win over the customer with our extensive cybersecurity expertise and certification in accordance with IEC 62443, achieving Security Level 2 here at the Serum Institute of India.
