Animal Health Production Facility

Industry

Pharmaceutical

Business Issue

The client implemented a project to shut down an outdated, manually run production facility and replace it with a modern, automated facility that complied with current GMP standards.  The facility was built to produce animal heath products.

Project Summary

This project introduced automation to a fully manual plant.  As a validated facility, the customer needed expertise to direct them in validating an automated facility. 

This facility consists of OEM skid mounted equipment, stick built processes and utilities with a total of 3,000 I/O points.  This equipment includes equipment prep, media prep, blending, fermentors, bioreactors, filtration, formulation, filling, freeze-drying, clean and plant utilities. 

The automation system also needed to integrate all of the OEM equipment installed in the plant.

Scope Responsibility

Cornerstone Controls was responsible for the following areas:

  • Project management of process control engineering team.
  • Automation engineering design and development of Rockwell PLC and Wonderware HMI systems. 
  • Systems included:
    • Steris Autoclaves
    • Getinge Cabinet Washers
    • Blenders
    • WB Moore Fermentors
    • WB Moore Bioreactors
    • Formulation/Media Prep
    • Hartel CIP
    • Filtration
    • WFI
    • TL/Bosch Filling
    • Serail Freeze Dryers
  • System integration of all plant systems to plant SCADA/Historian.
  • Software validation of new systems including developing and executing the Master Validation Plan, Test plans, Test Cases and Installation and Operation Qualifications.
  • Control system panel design and build.
  • Management of electrical contractors.
  • Instrumentation purchase, calibration, and installation.

Results

The facility was successfully automated and validated within budget and on time.