Reducing Downtime in Biopharma Manufacturing with PLCs

In the biopharmaceutical industry, reducing downtime is not only a matter of efficiency but is important for meeting strict regulatory standards, maintaining production quality, and controlling costs. With continuous advancements in automation technology, Programmable Logic Controllers (PLCs) have emerged as an important tool for minimizing downtime in biopharma manufacturing.

GL-Tec takes a look at how PLCs can streamline biopharma production processes, minimize unexpected failures, and contribute to greater productivity and compliance.

Understanding PLCs in Biopharma

PLCs are industrial-grade computers designed to control and monitor equipment and processes. They are built to withstand harsh environments and provide reliable automation solutions. In biopharma manufacturing, where production processes require precise and consistent control, PLCs play an important role in various operations, from material handling to process monitoring and data collection.

The advantages of PLCs in biopharma extend beyond simple automation. They integrate with a wide range of equipment, are highly customizable, and provide real-time data analysis and monitoring capabilities. By implementing PLCs, manufacturers can gain a clearer picture of their processes, allowing organizations to maximize production and reduce unnecessary downtime.

Minimizing Unscheduled Downtime

Unscheduled downtime is one of the costliest issues in biopharma manufacturing. Interruptions can lead to wasted materials, decreased product yield, and extended production times. PLCs are designed to handle a wide variety of tasks in real-time, making them essential for maintaining operations.

Here are a few ways PLCs can help:

Predictive Maintenance: PLCs collect data from connected sensors and equipment, which can then be analyzed to predict when a component may fail. This predictive approach allows maintenance teams to address potential issues before they cause downtime, which reduces the likelihood of unexpected disruptions.

Real-Time Alerts and Diagnostics: PLCs are programmed to monitor specific parameters, including temperature, pressure, and flow rate, which are vital in biopharma production. If a parameter exceeds acceptable limits, the PLC can immediately trigger an alert, allowing operators to address the problem before it escalates.

Integration with SCADA Systems: When PLCs work alongside Supervisory Control and Data Acquisition (SCADA) systems, operators gain centralized control and visibility into all production processes. This integration allows quick identification of issues and can facilitate automated responses to prevent downtime.

Improving Production Efficiency

In a field where precision is a requirement, improving production efficiency through automation is invaluable. PLCs allow biopharma manufacturers to improve efficiency in several ways:

Automated Batch Processing: Many biopharmaceuticals are produced in batches, with each step of the process requiring specific conditions. PLCs can automate these conditions to verify accuracy, repeatability, and adherence to regulatory standards. Automated batch control also minimizes the risk of human error, reducing the need for rework and improving overall yield.

Resource Allocation: PLCs can control multiple machines and processes simultaneously, making it easier to allocate resources efficiently. This capability is especially valuable during periods of high demand when minimizing waste and maximizing production are critical.

Flexible Manufacturing Capabilities: PLCs can be reprogrammed to accommodate changes in production requirements, such as the development of a new drug. This adaptability is important for a rapidly evolving industry like biopharma, where new products frequently enter the pipeline.

Improving Compliance and Traceability

Biopharmaceutical manufacturing is subject to strict regulatory requirements. Compliance failures can lead to costly fines and damage to a company's reputation. PLCs contribute to a more compliant and traceable production process:

Data Logging and Traceability: PLCs can log critical data at every stage of production, from raw materials to finished products. This data can be stored and accessed later to meet compliance requirements, facilitate audits, and improve traceability.

Automated Reporting: PLCs can generate reports based on pre-configured criteria, making it easier to meet regulatory reporting requirements. Automated reporting also simplifies data analysis, allowing manufacturers to improve quality assurance processes.

Environmental Monitoring and Control: Certain environments, such as cleanrooms, must be strictly controlled in biopharma manufacturing. PLCs allow for real-time monitoring and control of factors like air quality, humidity, and temperature, validating compliance with regulatory standards.

Reducing Energy Consumption and Costs

The energy demands of biopharma manufacturing facilities are significant, and reducing energy consumption can have a direct impact on operational costs. PLCs help manufacturers minimize energy use without compromising product quality:

Energy-Efficient Process Control: PLCs can optimize energy consumption by automatically adjusting process parameters to match current production needs. This approach reduces energy waste during periods of low production or downtime.

Energy Monitoring and Analytics: By integrating PLCs with energy monitoring systems, manufacturers can analyze energy use patterns and identify areas where energy efficiency can be improved. This analysis can guide future investments in energy-saving technologies.

Facilitating Scalability and Future-Proofing

In the fast-paced biopharma industry, manufacturers must be prepared to scale up or modify production to meet changing demands. PLCs offer the flexibility needed to accommodate growth and evolving technology:

Modular Design for Easy Expansion: Many PLC systems are modular, allowing for easy expansion without overhauling the entire automation system. This modularity allows manufacturers to scale production capacity without significant downtime or disruptions.

Adaptation to New Technologies: As biopharma manufacturing increasingly embraces Industry 4.0, PLCs are compatible with emerging technologies such as IoT sensors, machine learning algorithms, and cloud-based data platforms. This compatibility makes it easier to integrate these new technologies, increasing productivity and reducing future downtime.

Case Study: Implementing PLCs for a Major Biopharma Manufacturer

To illustrate the impact of PLCs on reducing downtime, consider a case study involving a major biopharmaceutical company. Before implementing PLCs, the manufacturer faced frequent unscheduled downtime due to equipment failures and an inability to monitor critical process variables in real time.

By integrating PLCs with their existing manufacturing systems, the company achieved several improvements:

Reduced Downtime by 35%: With real-time monitoring and predictive maintenance capabilities, the company significantly lowered downtime across its production lines.

Increased Production Yield by 15%: By automating batch processing and maximizing resource allocation, the company improved yield while maintaining product consistency and quality.

Improved Regulatory Compliance: The automated data logging and reporting functions of the PLCs simplified compliance with regulatory standards, saving time and reducing the risk of compliance violations.

The Role of PLCs in Shaping the Future of Biopharma Manufacturing

PLCs have proven to be instrumental in reducing downtime, improving production efficiency, improving compliance, and controlling costs in biopharma manufacturing. By adopting these advanced automation tools, biopharma manufacturers can increase productivity while meeting the strict quality and regulatory standards of the industry.

As the biopharma industry continues to evolve, the role of PLCs will likely expand, incorporating more advanced data analytics, IoT integration, and machine learning capabilities. For manufacturers seeking to stay competitive and efficient, implementing PLCs is a step toward a more resilient, adaptable, and cost-effective production environment.

About GL Technologies

As a full-service company specializing in equipment calibration, repair, and certification services for biopharmaceutical, pharmaceutical, and medical device industries. Our team has extensive experience working with sPRT calibrations along with CMMS software, HPLC OQ validation, and fume hood certifications. Companies of all sizes rely on our team to implement, maintain, and keep their research and manufacturing processes compliant with regulatory standards. Other specialties include building maintenance systems, and mass spectrometry calibrations. For any centrigue calibrations or repairs, we service all of San Diego, Orange County, Los Angeles, and San Francisco!