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Strategic Integration Guides for Pharmaceutical Control Systems

How we helped a leading pharma provider streamline hardware integration with comprehensive DCS connectivity guides, OT documentation, and simulation logic strategies.

Industry

Pharma

Scope

Technical Documentation / System Integration / Connectivity Architecture

Timeframe

1 month

Technology

  • IT/OT Integration (OPC-UA)
  • OT (SCADA/Aveva System Platform/Historian)
  • OT (PLC/Codesys Software)
  • Java (SpringBoot, SpringCloud)
  • TypeScript (React)
  • MS-SQL

100%

alignment between hardware objects and DCS supervisory layers.

The client

A leading provider in the pharmaceutical industry specializing in downstream process equipment, such as Tangential Flow Filtration (TFF) systems. The client focuses on delivering high-end hardware that requires seamless integration into various end-user environments.

Business needs

The client identified a critical market need for end-users who purchase hardware without the original software suite. These users must integrate the equipment independently into their own supervisory systems, such as SCADA or Distributed Control Systems (DCS). To facilitate this, the client required standardized, comprehensive integration guides to ensure technical compatibility and reduce time-to-market for final installations.

The challenge

  • 01

    Complex Connectivity Mapping Precisely describing the physical and logical connections to diverse Distributed Control Systems (DCS).

  • 02

    System Component Instantiation Documenting how to integrate and instantiate existing OT objects within physical hardware components, such as Control Boxes and Pump Carts.

  • 03

    Scalability and Adaptation Designing the integration framework to prioritize future growth and adaptation without requiring significant reinvestments in new technology.

  • 04

    Standardization of Logic Documenting the safety, security, and simulation logic required for PLC testing on virtual machines without needing physical device connections.

Our solution

We provided a comprehensive suite of technical documentation and integration strategies designed to bridge the gap between pharmaceutical hardware and supervisory control software.

  1. Detailed Integration Deliverables

    Creation of exhaustive guides covering DCS connection descriptions, network configurations, hardware lists, and signal lists.

  2. OT Component Documentation

    In-depth control descriptions for each system device, ensuring that software and hardware components work flawlessly together.

  3. Testing and Validation Framework

    Documenting simulation strategies on virtual PLCs to enable rigorous testing before physical implementation.

  4. Biotech-Specific Application Guides

    Ensuring the documentation covers diverse processes, including media preparation, viral inactivation, and antibody drug conjugation.

Technology used

  • IT/OT Integration (OPC-UA)
  • OT (SCADA/Aveva System Platform/Historian)
  • OT (PLC/Codesys Software)
  • Java (SpringBoot, SpringCloud)
  • TypeScript (React)
  • MS-SQL

The outcome

The resulting documentation provides a scalable and reliable foundation that enhances productivity and flexibility in pharmaceutical manufacturing.

  • Standardized Integration
  • Reduced Implementation Risk
  • Enhanced Scalability
  • Market Competitive Advantage

What we implemented

  • DCS Connectivity Guides Step-by-step instructions for physical and logical network integration.
  • Signal & Hardware Mapping Comprehensive lists for seamless data collection and real-time visualization.
  • Process Control Descriptions Detailed logic for remote monitoring and user-friendly interfaces.
  • Virtual Testing Logic Strategies for PLC simulation to ensure software/hardware compatibility.
Krystian Maskulanis
This project required a seamless integration of cutting-edge technology with robust project management practices. The key to success was maintaining transparent and continuous communication with customer teams, ensuring all stakeholders were aligned while focusing on technical proficiency. Our commitment to high coordination and problem-solving guided the project toward meeting its strategic objectives in system documentation.
Krystian Maskulanis — Industrial Systems Engineering Lead

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