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ZETA USA| Services | Automation & Control
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Automation & Process Control

Automation solutions for biopharmaceutical manufacturing systems.
Integrated control architectures supporting reliable, scalable, and GMP-compliant production.
Speak with an Automation Engineer
A person in full protective gear operates a touch screen in a clean, sterile lab with complex stainless steel machinery.
Three people are standing in front of an open electrical control panel. One holds a tablet, another a clipboard with papers, and the third has their back to the camera.

Comprehensive and customized. Our automation services.

As a leader in customized automation solutions, we provide automation at all levels. Whether your facility operates with stainless steel, single-use technologies, or a hybrid thereof, we seamlessly integrate your pharmaceutical production systems into a new or existing automation environment.

 

Stainless steel platform for integration of four single-use bioreactors

Single-Use Bioreactor Integration

Automation for Hybrid Stainless Steel & Single-Use Systems

ZETA’s automation team delivered a fully customized control solution integrating multiple single-use bioreactors into an existing GMP production environment. By aligning control strategy with process requirements, the system supports operational stability, flexible batch execution, and scalable replication across production lines.

Success Story
Mobile skid in production area docked with tubings to the docking station on the wall

Modular Pilot Plant Automation

Automated Control for Multiproduct Plasma Processing

Our team engineered and automated a modular pilot plant supporting mobile process units with intelligent docking and system recognition. The platform enables continuous operation, structured control logic, and long-term flexibility for evolving plasma processing requirements.

Success Story
Illustration of a sustainable city concept featuring wind turbines, solar panels, industrial buildings, and residential structures on a floating piece of land above water.

Facility Automation Expansion

Scalable Automation for a Growing CDMO Facility

ZETA expanded an initial energy monitoring installation into a fully integrated facility management and automation platform. By coordinating utilities, process control, and site-wide automation architecture, the system evolved alongside the facility’s capacity growth while maintaining regulatory alignment.

Success Story
Piping under platform

Stainless Steel & Single-Use Integration

Unified Control Architecture for Complex Biopharma Production

In a major production expansion, ZETA automated both stainless steel and single-use systems within a unified control platform. Our automation team integrated equipment and control architecture to support consistent GMP operation, flexible production strategies, and long-term scalability.

Success Story

Capabilities across project and facility lifecycles. Our automation portfolio.

ZETA’s automation capabilities range from integrating individual skids and systems into existing control environments to delivering comprehensive process control architectures for regulated biotech manufacturing facilities.

Integrated Automation for Engineered Systems

Turnkey automation developed in coordination with process engineering and equipment fabrication.
PLC and DCS-based control systems Batch strategy development Skid-level and system-wide integration Supplier-independent system integration

Advanced Control & Technology Integration

Our automation solutions support evolving manufacturing environments and enable flexible system integration while maintaining GMP compliance.
MTP (Module Type Package) implementation Single-use system integration Control system expansion and modernization Automation support for specialized systems (e.g., freeze & thaw)

Standalone Automation & System Support

Automation services delivered independently of full facility projects. These services support operational continuity and modernization within existing facilities.
DCS/SCADA upgrades Control system migrations Integration of new skids into existing platforms Managed automation services

Integrated engineering & EIC execution. Cross-disciplinary alignment.

EIC Integration

Electrical, instrumentation, and control engineering are developed in coordination with automation architecture to ensure aligned hardware, control logic, and process execution.

Integrated Project Delivery

Process, automation, EIC, and project teams coordinate throughout execution to support schedule certainty and fast-track implementation.

Process-Aligned Control Strategy

Automation design reflects real process behavior, ensuring control logic supports performance, stability, and GMP compliance.

Single-Use System Integration

Single-use systems are integrated into new or existing control environments, regardless of supplier, with consistent architecture and validation alignment.

Vertical Integration

Process automation platforms are aligned with customer software environments to support structured data exchange and operational visibility.

Extended automation capabilities. Integrated digital & simulation support.

ZETA collaborates with specialized automation and digital partners, including SIGMA Process & Automation and INOSIM, to extend technical depth where required.

Process Optimization & Consulting

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Digital solutions supporting automation architecture, data integration, and operational visibility across regulated manufacturing environments.
Process Optimization

Process Simulation tool INOSIM Insight

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Simulation-based support for validating automation strategies and process configurations during plant design and optimization.
INOSIM Insight

Predictive Decision Support Tool INOSIM Foresight

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Real-time predictive decision support integrated with batch manufacturing operations to enhance automation-driven performance.
INOSIM Foresight
The image shows three people working together in an industrial setting. One is adjusting equipment with pipes and valves, another is using a tablet to monitor or record data, and the third is working inside an open electrical cabinet with wires, also using a tablet. The image shows a clean, modern industrial facility with large metal tanks and complex piping. Some equipment has digital overlays, suggesting the use of augmented reality or smart monitoring. The floor is blue, and the space is brightly lit and well-organized. The image shows a person in protective clothing working with large metal equipment in a clean industrial setting. Behind them are two transparent screens showing charts and graphs, suggesting the use of advanced technology to monitor processes.

Specialized automation capabilities Solutions for complex challenges

Automation projects often extend beyond core control architecture. These focused capabilities support complex, regulated manufacturing environments.

MES and MOM project support
Stainless steel and single-use automation
Controlled Freezing & Thawing Automation
The image shows a person in protective clothing working with large metal equipment in a clean industrial setting. Behind them are two transparent screens showing charts and graphs, suggesting the use of advanced technology to monitor processes.

IT/OT coordination

ZETA supports integration of automation platforms with MES and MOM systems to ensure coordinated data flow and operational alignment. Services include IT/OT coordination, vendor oversight, system integration planning, and structured project execution within regulated manufacturing environments.
Stainless steel platform for integration of four single-use bioreactors

Integration of stainless steel and single use-systems

Automation strategies support integration of stainless steel and single-use systems within unified control environments. Customer-specific standards are implemented through structured control architecture, ensuring consistency, flexibility, and GMP alignment across hybrid manufacturing platforms.
The image shows a person in protective clothing working with industrial equipment. They’re using a tablet near an open control panel full of wires and electronics. Next to them is a large metal tank with pipes and valves.

Automation support for controlled freezing and thawing processes

This includes temperature regulation, recipe management, audit trail integration, and connectivity with higher-level control systems.
Where appropriate, ZETA’s FreezeControllers provide a fully integrated control solution designed for regulated manufacturing environments. These systems can be implemented as standalone solutions or integrated into existing automation architectures.

Reliable Manufacturing Depends on Integrated Automation

Connect with ZETA’s automation engineers to discuss control strategies, system integration, and scalable manufacturing architectures for regulated biopharmaceutical environments.
Speak with an Automation Engineer

Success Stories

The image shows three people working together in an industrial setting. One is adjusting equipment with pipes and valves, another is using a tablet to monitor or record data, and the third is working inside an open electrical cabinet with wires, also using a tablet.

Modular Pilot Plant Automation

Ongoing automation support for multiproduct plasma processing plant.
Close-up view of a pharmaceutical production line with multiple glass vials filled with a clear blue liquid, each sealed with a red cap, moving along a conveyor system in a sterile manufacturing environment.

Stand-Alone Simulation: Optimizing a Fill & Finish Facility

ZETA validates the planned capacity for a greenfield facility and saves a €5 million investment by using simulation expertise.
Person in cleanroom clothing in production area, mobile skids connected with hoses to the ceiling

Combining Stainless Steel and Single-Use

Stainless steel preparation plant and single-use filtration system integrated with Siemens PCS7 process control system.
Integrated pharma & biotech expertise – direct to your inbox.
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