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Pharmaceutical

InduSoft Web Studio has played a major role in the Pharmaceutical industry in everything from food and drug packaging and storage, to pharmaceutical manufacturing that must adhere to strict guidelines, such as the FDA 21 CFR Part 11 and EU Annex 11 standards. InduSoft Web Studio has passed major audits from top pharmaceutical companies, and can provide the tools to create a compliance-ready SCADA software solution for the pharmaceutical industry.

Pharmaceutical

GAMP, FDA 21 CFR Part 11, and EU Annex 11 Compliance

InduSoft Web Studio has all the tools required to make a project that adheres to FDA 21 CFR Part 11, EU Annex 11 and GAMP (Good Automated Manufacturing Practice) guidelines. Functionality such as security, e-signatures and traceability, batch reporting and automatic writing to any SQL database are some of the tools that can be employed to maintain a fully compliant process that will meet international standards for food and drug and pharmaceutical manufacturing. The ability to store and record data for each batch makes it easy for representatives of the FDA and EU Annex to audit and verify data.

InduSoft Web Studio Database Connectivity

InduSoft holds a patent on the ability to connect to any SQL database from embedded Windows operating systems. InduSoft Web Studio has powerful database connectivity features, making it easy to meet the stringent logging requirements necessary in the pharmaceutical industry. Databases can be easily configured for redundancy and store-and-forward configurations ensuring that critical data requirements are met.

Built-in Recipe Functionality

Facilitate easy product changeover with the built-in recipe functionality of the InduSoft Web Studio SCADA software platform. Virtually eliminate human error by enabling the necessary checks using barcode scanning, 2D matrix and RFID data collection. Integrate seamlessly with vision systems to ensure the right product is in its appropriate packaging.

Proper Warehousing Conditions Easy to Monitor

With a full SCADA solution developed on the InduSoft Web Studio platform, it’s easy to monitor and verify warehouse conditions such as air quality, temperature, and humidity. Provide accurate data for storage conditions by utilizing InduSoft’s ability to connect to virtually any device, from temperature controllers to HVAC and filtration systems.

Hardware Independent

Run InduSoft Web Studio on any Windows PC, including the NEMA 4x, IP65 and stainless steel mounted PCs that provide a sterile and safe surface in pharmaceutical manufacturing. For more information on the types of panel PCs available with InduSoft Web Studio’s SCADA software already installed, please see our list of certified hardware manufacturers.

From individual machine or material handling HMI to large scale supervisory stations InduSoft Web Studio SCADA HMI software offers everything required for a powerful solution.

IWS tools for FDA 21 CFR Part 11


Pharmaceutical Case Studies

Published on Wednesday, March 28, 2012

Creating the Building Automation System for One of Indonesia's Largest Shopping Centers

Designing and implementing the building automation system for the Karawaci Supermal was a success, thanks to MOSCADS and their InduSoft Web Studio solution.

 

MOSCADS Case Study
  • InduSoft Web Studio was used to create a building automation system for Karawaci Supermal in Jarkarta, Indonesia.
  • The application  controls the scheduling of the building’s energy use, as well as monitoring systems all over the facility.
  • The savings of energy consumption costs have been substantial since the new system was developed, and managers and operators can view data from all over the facility and make quick changes or provide preventative maintenance.
Figure 1: The application monitors and controls different zones within the mall’s retail area.

Managing the many systems that make up a huge ecosystem of buildings is a challenging task. Luckily, as better tools are built and designed, any building automation project can be improved. Greater control of aspects of the system such as energy use, heating and cooling, HVAC systems, and even security leads to a more efficient building complex that can manage resources in the most cost effective way possible.

 

Karawaci Supermal, Located in Jakarta, Indonesia, is one of the largest family shopping centers in Indonesia. With the help of MOSCADS, the entire building automation system of the mall was overhauled with a building management system based around InduSoft Web Studio, providing huge cost savings benefits.

 

Background 

Karawaci Supermal is a massive structure that occupies nearly 12.5 acres of land in Jakarta, Indonesia. The building complex includes nearly 200,000 square feet of space, and consists of a compound divided into sections dedicated to certain types of retail spaces, from cinemas to department and hardware stores. The mall sustained looting and burning in a series of riots in 1998, and reopened under the name Lippo Supermall. Since then, the mall has continued to expand. In 2006, phase two of the supermall was opened to the public to offer a vast shopping experience.

 

Throughout these changes, operators of the building management system in the mall were in charge of operating the various systems, which included turning on and off electrical systems, air conditioning, and more. This was an inaccurate and inefficient system, as operators had to move to different areas of the facility to address different aspects of the system. Schedules were often missed, which could cause huge increases in costs.

 

The owners of Karawaci Supermal decided to invest in a building management system that could not only control and monitor the building using robust and reliable software, but also provide an informative graphical interface for operators to use.

 

Figure 2: The overview screen shows operators controls for different aspects of the BMS by zone.

Figure 2: The overview screen shows operators controls for different aspects of the BMS by zone.



The Challenge

MOSCADS stepped in to accept the challenge of developing a system that could control and monitor the whole building complex, including: the cooling tower, exhaust and intake fans, water pumps, circulation pumps, fire pumps, lighting, the high voltage transformer, the generator, and the temperature and air quality monitoring equipment.

 

Scheduling proved to be a big problem for the non-automated system. The system was most efficient when operators kept to a tight schedule that required turning systems on and off with precision timing. For example, the schedule might call for a fan to turn on a 9:55, and then the compressor to come on five minutes later, at 10:00. However, if operators were in that section of the facility, they might turn on both as 9:45 before moving to another room. While this made things easier for operators, it was far from efficient. In order to control costs, developing a schedule and automating equipment would be critical.

 

The building management system that the Karawaci Supermal required would be a new project designed from the ground up. This gave MOSCADS complete freedom to explore the top SCADA and HMI development platforms and choose one that best suited their customer’s requirements.

 

MOSCADS chose InduSoft Web Studio and developed a demo application to show to the client. The demo won over owners and operators because it was simple to use, and supported the unique demands of the mall’s building automation system.

Figure 3: This screen allows operators to monitor the power transformer room.

Figure 3: This screen allows operators to monitor the power transformer room.



 

The Solution 

The application built using InduSoft Web Studio connects to a variety of equipment using the Modbus/TCP protocol, and allows operators to access the system from across the facility using sixteen Web Thin Clients, with email functions that send out messages if an alarm occurs. The application monitors and controls the entire building automation system of the mall, and the remote viewing capabilities provide data to operators and the Supermal Karawaci management team all over the building.

 

Scheduling is controlled with the system, and protected through InduSoft Web Studio’s security features. Because of the costs associated with improper schedule adherence, the system security is divided into levels of access protected by usernames and passwords. Operators may monitor and start or stop equipment, but only the building maintenance manager can change the schedule. Mall management and other authorized uses can view the data remotely, but not control the equipment.

 

The system controls everything from the energy use to the water pumps and airflow of the mall. The flexible nature of InduSoft Web Studio makes it possible to connect to a variety of hardware using common communication protocols that are included with the more than 240 drivers, such as BACnet that are built into the SCADA/HMI software.MOSCADS Case Study

 

The Results

The main result of the installation of the new InduSoft project and user interface has been the money saved by controlling scheduling and automating equipment. The mall has seen energy efficiency rise considerably, and saved a substantial amount on costs by better controlling the schedules of equipment use. In addition, it’s far easier to monitor aspects of the system for potential problems, or provide preventative maintenance that will continue to help the mall increase the efficiency of their building automation system.

 

MOSCADS has leveraged the success of this operation by promoting a similar HMI for use in other business divisions of the mall owners, such as the apartment developer division. The Karawaci Supermal facility is only part of a larger corporate community that offers plenty of opportunities for development of more building management systems such as those used in the mall. But why stop there? According to Steve Rion, Chief Technical Officer at MOSCADS, "We plan to install InduSoft Web Studio in every building in the country!"

 

This year, the project will be upgraded to include more than 3,000 new hardware I/O points that gather data from across the new facility from systems such as the air conditioning, cooling tower, lighting, and power. Supermal is continuing to expand, and is building new floors this year, which will require additions to the building automation project designed by MOSCADS.

Figure 4: The cooling tower zone displays tower and pump status.

Figure 4: The cooling tower zone displays tower and pump status.

 


For more information contact your local distributor or InduSoft directly at

info@indusoft.com or 877-INDUSOFT (877-463-8763) or 512-349-0334.

 


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