SCADA System Calibration

SCADA, Supervistory Control and Data Acquisition systems play an important role in monitoring and controlling various manufacturing processes for biopharmaceuticals in the manufacturing process and drug production. For properly functioning SCADA systems, regular calibration is required. GL Technologies is a team of professionals that specializes in laboratory and manufacturing equipment calibration and certification for biopharmaceutical clients throughout California.

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What is a SCADA System in Biopharma?

SCADA systems in biopharmaceutical industries are used to monitor, control, and manage various critical processes involved in the production of pharmaceutical products. These systems gather real-time data from sensors and devices located throughout the laboratory and facility, giving workers the ability to remotely moitor and control different stages of the manufacturing process. SCADA also provides essential insights into variable such as temperature pressure, flow rates, and other key parameters to make sure the production environment remains within required conditions. By facilitating smart data acquisition and control, SCADA systems improve process reliability, productivity, and regulatory compliance.

Why Calibration is Crucial

Accuracy and Reliability

SCADA systems rely on various sensors, transmitters, and instruments to collect real-time data from manufacturing equipment and processes. Over the course of time, these components can deviate and become less accurate, leading to measurement errors and unreliable data. Calibration works to make sure the readings provided by SCADA systems are accurate and reliable, allowing for operators to make informed decisions and maintain process control.

Quality Assurance and Compliance

The biopharmaceutical industry as strict regulatory guidelines such as the cGMP (Good Manufacturing Practices), and GLP (Good Laboratory Practices). Calibration is a requirement for compliance with these regulations. By calibrating SCADA system components, manufacturers can demonstrate traceability of their process measurements, supporing quality assurance and regulatory compliance efforts.

Key Considerations for SCADA System Calibration

Calibration Schedule

Biopharmaceutical companies need to establish a well-defined calibration schedule to maintain the accuracy of SCADA systems. The schedule should consider the importance of process parameters being measured, the stability of the instrument, and compliance. A regular calibration schedule should be based on the manufactuerer's recommendations, should be established strictly adhered to.

Traceability and Documentation

Calibration processes need to following internatinally recognized standards and guidelines as outlined by the International Organization for Standardization (ISO_). Calibration records need to include the calibration date, equipment identification, the method used, standards used, and the technician or company who did the calibration. This documentation will provide traceability, allowing auditors and inspectors to verify the accuracy of SCADA system measurements.

Validation and Performance Monitoring

After the calibration is complete, it's important to validate the performance of the calibrated instruments to verify their accuracy against known standards. Performance monitoring should be an ongoing process, and any deviations should trigger correction action quickly. Regular performance the checks and validation tests identify potential issues before they impact process control and product quality.

Key Steps involved in the Calibration Process

Identify Calibration Requirements: The first step in the calibration process is to identify which components of the SCADA system require calibration. This includes sensors, transmitters, actuators, and any other relevant devices that contribute to data acquisition and control.

Establish Calibration Standards: Calibration standards serve as reference points against which the performance of SCADA system components is measured. These standards can be defined by industry regulations, manufacturer specifications, or internal quality control procedures.

Select Calibration Equipment: Depending on the type of sensors and instruments used in the SCADA system, appropriate calibration equipment must be selected. This may include temperature calibrators, pressure gauges, flow meters, and calibration software.

Perform Calibration Procedures: Calibration procedures involve systematically adjusting the settings of sensors and instruments to match the specified standards. This may include zero-point calibration, span calibration, and linearity checks. During this step, it's essential to record all calibration data accurately for documentation and traceability purposes.

Validate Calibration Results: Once calibration procedures are complete, it's crucial to validate the results to ensure that the SCADA system components meet the required accuracy criteria. This may involve conducting calibration tests under various operating conditions and comparing the measured values against reference standards.

Document Calibration Records: Documentation of calibration records is vital for regulatory compliance and quality assurance purposes. Detailed records should include information such as calibration dates, procedures followed, calibration results, deviations observed, and any corrective actions taken.

Implement Calibration Schedule: Calibration is not a one-time activity; it's an ongoing process that requires periodic maintenance. Establishing a calibration schedule based on industry best practices, equipment specifications, and regulatory requirements ensures that SCADA systems remain accurate and reliable over time.

Perform Maintenance and Recalibration: Regular maintenance and recalibration of SCADA system components are necessary to prevent drift and ensure continued accuracy. This may involve cleaning, inspection, and adjustment of components as needed to maintain optimal performance.

Training and Competency Development: Adequate training and competency development programs should be provided to personnel involved in the calibration process. This ensures that calibration procedures are carried out correctly and consistently, minimizing the risk of errors and discrepancies.

Continuous Improvement: The calibration process should be subject to continuous improvement efforts to enhance efficiency, reliability, and compliance. Regular reviews of calibration procedures, equipment performance, and feedback from end-users can help identify areas for optimization and refinement.

Education Corner

Unlocking Potential: SCADA Systems in Biopharma Production

In the intricate landscape of biopharmaceutical production, precision, efficiency, and safety are paramount. The demand for innovative therapies and vaccines is continually on the rise, requiring advanced technologies to meet quality standards and regulatory requirements. In this context, Supervisory Control and Data Acquisition (SCADA) systems have become the key tool, offering a comprehensive solution to monitor and control biopharma manufacturing processes. SCADA systems have long been used across various industries, but their application in biopharmaceutical production is particularly transformative. SCADA systems are continuosly unlocking the potential of biopharma manufacturing:

Why GL-Tec?

The GL Technologies team has the experience and equipment to calibrate all types of display equipment accurately. We understand the importance of accurate measurements in your specific industry, and we're committed to providing you with reliable, traceable calibration services.

Our calibration services are ISO 17025 accredited, and we follow strict quality control procedures. Your equipment is calibrated to the highest standards. We also provide fast turnaround times, so you can get back to work with minimal downtime.

GL Technologies Overview

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.