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Restoration: Establishing or Re-establishing a Complex Lab Ecosystem

A4BEE restored 100% connectivity for a global R&D hub in 3 months. Learn how we integrate complex lab OT with IT.

Industry

Life Sciences / R&D

Scope

System Integration / IoT / Connectivity / Network Segmentation / Disaster Recovery

Timeframe

3 Months

Technology

  • OPC UA
  • TCP/IP
  • VLAN Network Segmentation
  • SCADA
  • Industrial Drivers
  • BioHT / Vi-CELL / NovaFlex

3

Months - sprint to full set up.

6

New Device Types – Integrated into the data loop.

100%

Validation of data integrity post-construction.

The client

A major R&D hub undergoing significant physical reconstruction looking to restore and upgrade the "Digital Nervous System" of the lab to minimize downtime and resume critical research.

Business needs

The client sought to rapidly restore digital connectivity disrupted by physical reconstruction by integrating a heterogeneous mix of legacy equipment and new, advanced analyzers into a unified, secure digital platform under strict time pressure.

The challenge

  • 01

    Vendor Complexity Integrating devices from multiple vendors (Beckman Coulter, Roche, Hamilton) that use different communication protocols.

  • 02

    Network Security Implementing strict VLAN segmentation to secure the OT (Operational Technology) layer while allowing data flow to IT systems.

  • 03

    Operational Pressure The lab needed to be fully operational for science teams immediately after physical handover.

Our solution

We executed a "Digital Resurrection" strategy, running parallel streams of infrastructure connectivity and device integration to ensure a seamless Day-1 operation. The solution entailed:

  1. Vendor-Agnostic Integration

    Built custom drivers and connectors to ingest data from diverse instruments (Cell Counters, HPLC, Auto-samplers) into the central SCADA/Data platform.

  2. Network Orchestration

    Reconfigured the entire connectivity layer, ensuring secure and reliable data transmission from the edge to the cloud.

  3. Rapid Deployment Teams

    Mobilized a distributed team to validate data integrity from sensor to dashboard in real-time as physical devices were powered up.

  4. Legacy & Future Bridging

    Simultaneously restored legacy systems and onboarded new smart sensors, ensuring no gap in data continuity.

Technology used

  • OPC UA
  • TCP/IP
  • VLAN Network Segmentation
  • SCADA
  • Industrial Drivers
  • BioHT / Vi-CELL / NovaFlex

The outcome

The lab achieved full digital operability within the quarterly sprint cycle, with an upgraded device landscape. By restoring 100% connectivity and expanding the ecosystem, we ensured a seamless handover for scientists returning to the renovated facility with zero friction.

  • 100% Connectivity Restored
  • Expanded Ecosystem
  • Seamless Handover
  • Data Integrity

What we implemented

  • System Integration Centralized SCADA/Data platform integrating diverse instruments like Cell Counters and HPLC.
  • Connectivity Layer Secure and reliable data transmission reconfigured from the edge to the cloud.
  • Real-time Monitoring Sensor-to-dashboard validation ensuring data availability for all process units.
  • Device Onboarding Integration of 6+ new smart sensor and device types into the digital ecosystem.
Adrian Urban
Re-establishing a digital lab involves weaving a seamless web of connectivity that goes far beyond simple hardware installation. We harmonized a chaotic landscape of diverse machines into a symphony of data, ensuring the science could continue without missing a beat.
Adrian Urban — Software Engineer

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