New System Integration

A new type of System Integration offering...

RETROFIT & UPGRADING PROCESS In this issue: 50% productivity increase for SOFTWARE & a Pharma manufacturer Developing a high speed vision system for blister packs EQUIPMENT Solving legacy control problems by reverse News on the latest Pharmaceutical automation engineering projects designed, developed, manufactured and Leading edge vision implemented, with full software development and integration. inspection systems Celebrating 27 years as a Whether you are extending an existing production line, upgrading process equipment or leader in process technology building an entirely new plant, this is the essential read to ensure that your upgrade delivers on Put PAT into practice now production, efficiency and reporting targets. 2 | www.optimal-ltd.co.uk

“We automate and improve the performance and productivity of all types of FBD: large and small, fully automatic and semi automatic, new build and refurbished, solvent and non solvent based,” said Martin Gadsby, a Director of Optimal. “Using a range of automation vendor hardware and software, the systems we have supplied range from those with very traditional push button controls, through systems with HMI interfaces, to those with full-blown Client Server SCADA and even DCS.” www.optimal-ltd.co.uk | 3

Optimal legacy control system upgrade of fluidised bed dryer delivers 50% increase in productivity for pharma manufacturer

Optimal Automation has highlighted and client specific Batch Reports simple end point determination – its ability to automate and improve are generated, these being used by building Orchestrations (PAT the productivity of fluidised bed as part of the total batch release Methods), Process Models, and dryers, following the upgrade of documentation set. The investment gaining process understanding, the a legacy control system to a PLC by the pharmaceutical manufacturer client was able to determine - in real and networked SCADA system on in the Optimal solution has been time - the drying phases that were a large FBD, for a major blue chip paid back swiftly, via the 50% occurring in the drier. He was then pharmaceutical client. By closely increase in productivity that has able, by means of the Orchestrations working with the client, in relation been achieved. within synTQ®, together with a 3rd to optimising the efficiency of plant party control system and the OPC operation, Optimal have been able In another recent project, a leading connection from synTQ®, to design to deliver a staggering 50% increase manufacturer of pharmaceuticals an application that controlled the in productivity for the FBD. installed Optimal’s synTQ® PAT drying temperature in line with the (Process Analytical Technology) Data stage of the process, as determined The replacement of a legacy control Management system on a fluidised by synTQ®, and introduce real time system, in the most recent of bed drier. The initial objective of dryer end point control. The system Optimal’s FBD projects, involved a the installation was to determine has proved to be very successful, control strategy that encompassed if positive gains could be made, in and has, once again, delivered a not only tower automation, but also terms of the consistency of quality short payback time, maximising ROI. all the batching of raw materials, and in terms of reducing processing including dispensary control, time, by using real time moisture This was a relatively simple 1st together with tracking of raw monitoring and control to reduce the PAT project for the client, however materials and finished product cycle time and determine in real time having started with a simple project in IBCs. The system supplied by the process end point. that proved the worth of PAT, the Optimal to achieve these objectives client has gained PAT deployment has a Siemens PLC plus a client In this project, synTQ® was used experience and skills, and they server WinCC SCADA system at in combination with a 3rd party have proved to themselves that the its heart, the SCADA having four multivariate analysis (MVA) product technology works and can deliver clients plus an engineering station. and a NIR instrument. very real benefits. They now intend A sophisticated recipe system to optimise other aspects of their was integrated into the SCADA, The project was not however just processes by using PAT. 4 | www.optimal-ltd.co.uk

Optimal develops high speed vision system that inspects two sealed blister packs per second, with zero tolerance

Optimal Industrial Automation has Optimal undertook the high that had to be rejected, were overcome immense challenges speed inspection project after major issues that had not been to produce a high speed vision the pharmaceutical manufacturer addressed before in the industry. system for a major pharmaceutical had investigated buying a system These factors, together with the manufacturer that inspects for from a standard supplier, but none aforementioned problem of a highly seven key visual parameters was available. The company was reflective product, made the project relating to sealed blister packs at approached because of its track very challenging indeed, and two per second. record of executing complex vision were presumably why other vision inspection projects. “The client’s inspection companies had declined The packs are for the Japanese requirements were daunting,” to take it on.” market, have Japanese text, said Martin Gadsby, a Director of and must have both sides 100% Optimal. “He needed to inspect to The importance of the overprint inspected. The challenge is a standard that was higher than was of paramount: it is in Japanese compounded, due to the natural anywhere else: in effect, a zero characters and the system has (but acceptable) variation in the tolerance standard. In addition, to inspect it as such. Without an blister packs, and the fact that the speed of the line and the very effective inspection system to they are made from aluminium foil, small visual differences between perform this function, the production which is highly reflective. the required standard and those process would have been at best www.optimal-ltd.co.uk | 5

The specification for the vision inspection system called for seven quality factors to be inspected. These were: Correct lot code and expiry date; correct overprint with no defects; and verification that there were: 1. No scratches, 2. No dents, 3. No marks 4. No holes and 5. No surface contamination of any kind on the blister pack.

inefficient; at worst, the company with the lighting techniques and Having developed the system would not have been able to export its regulatory compliant operator we then tested it extensively. the product to Japan. interface software for machine vision Unfortunately, accurate detection - synTI®, the specialist software is of the blisters still proved to be a The task of providing a vision able to produce excellent and robust problem, because if they are not system to meet the customer’s results that is also easy for the detected entering the system at requirements involved Optimal in operators to use. exactly the correct time, then the - first of all - developing a detailed timing of the process is thrown understanding of the production Therefore, after much development, out. We trialled several sensing process and the product itself, and Optimal has produced a system techniques before settling on one then producing a technology leap that integrates high speed digital that addressed this problem. in both hardware and software cameras, lighting, image analysis to achieve success. As with techniques and a software package Then, once the lighting was most vision inspection systems that identifies sub-standard packs optimised and the timing of the the lighting was critical. Optimal correctly, so as to trigger their products passing through the undertook a significant research rejection from the production line. system was made robust, the and development programme where image analysis was optimised by it developed a range of lighting “The fact that the blister packs developing the image analysis techniques that had to be used reflect light made the acquisition of algorithms in the high level software. in a specific sequence in order to useful images very difficult, and also The final system was then tested provide the desired effects, whilst increased the difficulty of being able against product directly coming from not being affected to too great an to see the desired surface defects to the production line, to ensure that all extent by the natural variations that the required resolution,” said Martin of the naturally occurring variations occur in the blister packs. Gadsby. “Also, the blister pockets had been catered for. Once this was naturally move in each blister: not a achieved, the system was formally In addition to lighting techniques, huge amount, but sufficient to make validated and passed for production Optimal also developed specialised a simple direct image comparison purposes. It is now in daily operation software technology that would invalid. To overcome these and we are looking to build upon enable the required image analysis problems, multiple images using its success by talking to other to occur in a real time, and produce differing lighting techniques were customers that are interested in the the desired responses despite the found to be necessary, all of these technology.” natural and acceptable variation in having to be correctly synchronised the blister packs. In combination to each blister pack. 6 | www.optimal-ltd.co.uk

Optimal industrial automation solves problem of legacy control, with re-engineering of DCS, PLC, SCADA and MES systems

control system upgrade is left until the failure occurs, then there will be a high pressure situation for all involved to get the new system in and running again as quickly as possible. As a result, production improvements will be low on the priority list and will not be implemented.”

After the upgrade the system will, With the ending of the first Now, by working closely with users therefore, continue to run as it generation of factory automation, of legacy systems, Optimal Industrial did previously, and any potential there are an increasing number of Automation is able to provide a improvements that could have control systems that are becoming solution to these problems. By given a meaningful payback will obsolete, presenting a major using skills and experience built up have been lost. problem of replacement to the over 27-years, Optimal is able to system user. These ‘legacy’ control reverse engineer most processes, The process of upgrading a systems, as they are known, are allowing the replacement of any legacy control system involves difficult to maintain and support. control system – irrespective of type Optimal in surveying the system, Spare parts are a problem, and or make – with a modern equivalent understanding its functionality finding skilled personnel to provide that is well documented and fully and then preparing a detailed system support, both hardware and supported. functional design specification for software, becomes increasingly a replacement system. Optimal difficult. “There are a number of very is uniquely qualified to perform good reasons for replacing, or these functions, as it has its own What all this means for the system implementing the upgrade of a complete in-house electrical user is that the control system legacy control system before it design and build capability, that has been running his process fails,” said Martin Gadsby, a Director where full systems can be reliably for the past several years of Optimal. “The first of these designed and manufactured. This is increasingly operating upon is Timing. The change over to a is complemented by software borrowed time. Moreover, to new system can be timed to suit services that cover the full compound matters, when the production demands, and so the spectrum, from PLCs through system does fail, it will probably impact on production is minimised. SCADA to DCS, plus high level be at the worst possible time for The second is Cost. An upgrade languages such as C# & VB DotNet, production; and getting it to run executed under an emergency and database work, including again will be difficult, and almost situation will cost more, not only real time industrial databases. certainly time consuming, because, in the short term, but also the long In addition, Optimal also has the very often, documentation and term as any payback potential will skills to configure and programme even the software for legacy have been lost. Third, and final, is machine vision systems, servo systems is lacking. Functionality Improvements. If the systems and robots. www.optimal-ltd.co.uk | 7 Optimal celebrates 27 years of process automation Optimal Automation, a world leader in data management and PAT implementation, plus - one of the UK’s premier designers, builders, programmers and installers of PLC, SCADA, DCS, MES and vision systems, celebrates its 27th anniversary in 2014.

Optimal is one of the leading select number of companies that and software solutions for SMEs as developers and integrators of have been audited, examined, well as Global multinationals, our process analytical technology (PAT) and through displaying extensive commissioning teams will travel solutions for the Life Sciences and experience, have been approved virtually anywhere in the world to Chemical sectors using its own as high level integrators for the install equipment and software in-house developed synTQ data Simatic WinCC and PCS7 product solutions.” management software. The software ranges including FDA 21 CFR Optimal’s modern purpose built is used independently all around the Part II compliant projects in the factory is strategically located on the world and is also part of a Global pharmaceutical industry. Westerleigh Business Park, at Yate Marketing Alliance with Emerson Martin Gadsby. “We work with near Bristol. The factory enables Process Management. the majority of the top tier global Optimal to provide a complete in- Optimal is also a market leader in Life Sciences companies on house design and build capability vision systems - manufacturing automation and PAT projects, and covering all aspects of automation. its own 21 CFR Part 11 compliant have designed and implemented These include: packages. As a generalist automation projects for Automotive, • Huge & diverse software capability automation system integrator the Food and Drink, Chemical, Power • Electrical & electronic design + company is also very well respected, Generation and Aerospace build as is evidenced by its appointment companies that improve quality, as a Tier 1 Solutions Provider for throughput and time to market.” • Special purpose machinery design Siemens, an Approved Systems + assembly International commissioning and Integrator for ABB, and a Software • Complete unit operational test + support Solutions Provider for Rockwell development Optimal is a truly international Automation. organisation, handling projects • Full documentation + validation services In addition, Optimal has for some globally. “Since we design and years been an approved Siemens build special purpose machines • International installation + WinCC Professional and PCS7 in addition to developing and commissioning Integrator. This comprises a very implementing automation hardware • Training + technical support

Optimal Industrial Automation Limited Goodrich Close, Westerleigh Business Park, Yate, Bristol, BS37 5YT, United Kingdom T: +44 (0) 1454 333 222 F: +44 (0) 1454 322 240 E: [email protected] W: www.optimal-ltd.co.uk Industrial Automation

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