Industry
- Lifesciences (LDM)
Technology Focus
- iFIX HMI/SCADA
- Rockwell Automation Studio 5000 PLC Software
- Rockwell Automation FactoryTalk® Batch
- SQL Database
Project Overview
This life sciences company relies on automated liquid dosing manufacturing (LDM) to achieve precise formulations and maintain consistent product quality. To ensure their systems operate at peak efficiency, NeoMatrix performed a comprehensive upgrade of their SCADA system, transitioning to the latest version of iFIX and overhauling SCADA graphics for a more advanced and intuitive interface. Additionally, we integrated Rockwell FactoryTalk Batch for seamless recipe management and robust reporting capabilities, enabling enhanced operational control and data-driven decision-making.
To further enhance production capabilities, the company invested in two new filtration skids, both requiring end-to-end programming and automation.
Solution
Needing to start from the ground up, the company engaged NeoMatrix to develop and implement a tailored automation program to integrate the filtration skids seamlessly into their existing system.
To integrate the new filtration skids into the existing iFIX SCADA system, NeoMatrix leveraged its expertise to develop a modernized standard for filtration equipment. Using Rockwell Automation’s FactoryTalk Batch in conjunction with the PLC, we created a fully modular batch system with flexibility specifically tailored for the liquid dosing manufacturing process. The main goal of this batch system was to create flexible building blocks in the PLC and FactoryTalk Batch equipment editor. Built this way, the customer has the necessary tools to have full freedom to create any recipe that the system would require on the FactoryTalk Batch Recipe Editor.
NeoMatrix took the lead on the process design. We collaborated closely with the company's LDM engineering team, presenting a redesigned process that not only adhered to industry standards but also enhanced overall system functionality and maintainability. This proactive leadership ensured that the programming and process design met the company’s operational goals and quality expectations.
Results
The newly developed standard not only optimized the integration of the new filtration skids but also established a scalable and repeatable framework for future expansions. By implementing this validated approach, the company can now bring new equipment online more quickly, efficiently reprogram existing systems and make any recipe the LDM process requires. The ability to leverage pre-validated, standardized components ensures consistency, reduces deployment time, and enhances scalability across operations.
Additionally, the onsite engineering team benefits from a simplified, intuitive system that makes it easier to implement changes, troubleshoot issues, and operate the code effectively after learning the standard. This fosters long-term operational efficiency and confidence in system management.
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