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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 life-saving immunobiological preparations that were previously in short supply in India and imported at high prices.
The challenge
Digitalization and improvement of sustainability
Sustainability and digitalization in brownfield sites must not be ignored. Consumption in factories must be optimized and the carbon footprint must be reduced – regardless of whether in existing systems or in new buildings. In this context and in addition to the challenges it presents, digitalization offers opportunities for increasing efficiency and therefore remaining competitive. Digitalization is the key to sustainable production based on data. This data must be collected and evaluated to achieve the highest possible degree of transparency regarding consumption and processes. This is because only those who know where their resources are consumed can use levers to minimize this consumption and optimize processes.
To obtain this data, the first step was to collect, save, and visualize the data of more than 300 machines and processes for connection to the SCADA system. A variety of different communication protocols and the connection of OT with IT were the challenge for the project. With the Data Collection Box, the desired data was acquired from the existing systems without endangering certification or ongoing operation.
Solution
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 remove emerging defects, for example, due to material fatigue, before they 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 comprehensive cybersecurity experience and certifications in accordance with IEC 62443, achieving security Level 2 here at the Serum Institute of India. This was extremely important for the pharmaceuticals company in order to protect recipes and vaccination production processes against unauthorized access, for example.
The openness of PLCnext Technology makes it easy to connect OT and IT securely and to operate various interfaces. Now, we can not only produce more efficiently and therefore more sustainably, but also protect our IP.
Advantages
Productivity increases: collecting, storing, and visualizing process data
Optimization through the use of artificial intelligence and machine learning
Improving sustainability with data transparency
360° cybersecurity in accordance with IEC 62443
60% reduction in engineering time with preconfigured Data Collection Box solution
Summary
A major advantage in this project was the openness 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 its translation 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 comprehensive cybersecurity experience and certifications in accordance with IEC 62443, achieving security Level 2 here at the Serum Institute of India.
