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Technical Article
Automation Solutions for Hybrid Biopharmaceutical Manufacturing
To support the expansion of a German pharmaceutical manufacturing site, ZETA integrated a stainless-steel preparation system and a single-use filtration system into a unified GMP-compliant Siemens PCS7 automation platform, enabling flexible, reliable, and centrally controlled biopharmaceutical production.
AutomationEngineeringProcess ExpertiseTechnical Article
Project Objectives
The customer required:
- Integration of stainless-steel and single-use equipment into one automation platform
- Consistent process control across multiple systems
- GMP-compliant batch execution and documentation
- High system availability and operational reliability
- Seamless integration with the site’s existing process control infrastructure
Automation Strategy
ZETA implemented a Siemens PCS7 process control system with SIMATIC Batch, integrating all process equipment within a centralized automation architecture.
Key elements included:
- Unified control of stainless-steel and single-use systems
- ISA-S88 compliant batch management
- GAMP5-based automation practices
- Centralized monitoring and visualization
- Integration into the customer’s existing PCS7 environment
Solving Complex Integration Challenges
One of the most demanding aspects of the project involved the use of mobile and interchangeable process equipment.
ZETA developed automation solutions that enabled:
- Identification of different vessel configurations
- Safe docking and undocking procedures
- Operation of mobile single-use filtration units
- Reliable communication within a redundant control architecture
- Flexible manufacturing without isolated automation systems
Results
The completed system provided:
- Centralized control of multiple process technologies
- Improved manufacturing flexibility
- High system reliability through redundant architecture
- Simplified integration with higher-level manufacturing systems
- A scalable automation foundation for future expansion
By combining process expertise, automation engineering, and system integration capabilities, ZETA delivered a unified automation solution that supports reliable and flexible biopharmaceutical manufacturing.
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Biopharma services.
