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ZETA USA| Success Stories | From Energy Monitoring to Full Facility Management
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From Energy Monitoring to Full Facility Management

From energy monitoring to facility control: Scalable FMS solution for a CDMO site.
Robust automation, real-time monitoring, and integrated data logging support operational reliability and environmental control across production suites.
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Smart Expansion, Seamless Integration. Scalable system powers growth at a US CDMO site.

What began as a straightforward Energy Management System (EMS) implementation evolved into a comprehensive Facility Management System (FMS) for a CDMO facility located on the US northwest coast. Initially focused on energy monitoring, the project expanded to include additional utilities and control logic, evolving into a robust solution for a growing production site.

The challenge

The remote location posed some challenges to the customer, who was faced with a shortage of local suppliers and qualified external support. ZETA’s technical expertise supported the project in addressing these challenges. The project entered implementation after the design phase was completed, requiring the development of detailed specifications and alignment with site-specific quality expectations.

The solution

Standardized, reliable, and future-proof

The customer sought a reliable, standardized system that would minimize validation efforts. After evaluating several automation platforms, they selected Rockwell’s FactoryTalk software and a ControlLogix PLC – a GAMP Category 4 solution offering both simplicity and configurability ZETA implemented a FactoryTalk View SCADA system using validated process library objects, replacing the previously used Ignition platform, which did not provide standardized, pre-qualified libraries. To ensure data integrity under all conditions, ZETA integrated an onboard historian module directly into the PLC. This enables continuous data logging, including during power outages or network disruptions.

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

Customer benefits

The new FMS provides enhanced environmental control across the new production suites, including:

  • Enhanced environmental control across production suites, HVAC systems, utilities, and water quality monitoring
  • Standardized reporting and centralized operational visibility
  • Real-time monitoring of critical facility conditions
  • Automated email and SMS alerts for rapid response to out-of-spec events
  • Improved operational reliability and long-term system efficiency

 

Scalable Facility Automation Supports Long-Term Operational Reliability

ZETA helps manufacturers implement integrated facility management and automation platforms that improve monitoring, environmental control, and operational visibility across growing production environments.
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Simulation-Driven Concept Design for a Large-Scale mAb Facility

Simulation revealed the facility’s true bottlenecks before equipment was ordered, helping the customer right-size capacity, evaluate single-use and stainless options, and make defensible investment decisions.
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Seamless Retrofit with ZETA BMRF for Enhanced Cleanability and Flexibility

Hygiene, flexibility, and process integrity – all in one retrofit. Tailored solution with a BMRF and CFD validation for a Northern European customer.
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Holistic Process Simulation for Facility Design

INOSIM powers plasma processing facility. Comprehensive simulation approach for peak performance.
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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.
Mobile preparation system front view

Solving the Separation Challenge for a Life-Saving Vaccine

ZETA resolved a complex downstream separation challenge and translated the solution into a full-scale production system.
Detail from skid, consisting from piöes, hoses, valves

Process Integration for Gene Therapy Production

Seamless incorporation of single-use equipment allows maximum flexibility. ZETA delivers full-scope expertise from concept to qualification.
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Combining Stainless Steel and Single-Use

Stainless steel preparation plant and single-use filtration system integrated with Siemens PCS7 process control system.
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.
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Multipurpose Pilot Plant

Fully automated multiproduct system covering clinical and routine production of new products in addition to pilot production.
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Single-Use Bioreactor Integration

Hybrid bioreactor system combines single-use flexibility with stainless steel reliability.
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A True Hybrid Facility for Biopharmaceutical Manufacturing

Hybrid biopharma facility sets new standards in single-use and stainless-steel integration.
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High-Precision Mobile Skids

High-precision LNP mixing systems for mRNA vaccines delivered across Europe and the USA.
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Engineering Excellence for Oral Drug Coating

Breakthrough in drug coating dispersion: 62% faster production with advanced mixing technology.
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High-Tech Plant for Antibody-Drug Conjugation

ZETA delivers cutting-edge ADC downstream processing system in record 18 months.
Integrated pharma & biotech expertise – direct to your inbox.
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