Stabilizing a Biotech Prototype Amidst Hardware Flux
Industry
Biotech / Pharma Manufacturing
Scope
Industrial Automation / PLC & HMI Development / Motion Control / Systems Commissioning
Timeframe
~4-5 Months (Base + Extensions)
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2
Complex prototype units delivered simultaneously
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5
Distinct bottle formats validated in Auto-Mode
-
100%
Adaptation to new sensor/motor architecture
01
CLIENT
A Global Advanced Technology Group providing specialized aseptic processing machinery for the pharmaceutical industry, focusing on high-precision unit operations for vaccine and sterile liquid production.
02
BUSINESS NEEDS
The client required urgent Control Engineering Support to deliver fully functional prototypes of two next-generation filling and closing machines. The goal was to finalize PLC/HMI software, support "Test Runs" in auto-mode for multiple bottle sizes, and execute FAT readiness verification.
03
CHALLENGE
To help our client achieve its goals, we overcome the following challenges:
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Hardware Instability
Reacting to mid-project migration from DC motors to Servo drives and replacing analog sensors, which required rewriting core logic blocks. -
Mechanical Constraints
Compensating for mechanical issues, such as drive collisions and design limitations in the transport system, through software adjustments. -
Scope Fluidity
Addressing emerging R&D discoveries through iterative extensions to the original scope without delaying the final handover.
04
SOLUTION
We provided a dedicated Control Engineering squad to execute a "Fix & Finish" strategy, stabilizing the codebase and adapting it to the final hardware configuration. The solution entailed:
- Adaptive Logic Development (PLC) Rewriting critical control modules for the Transport Conveyor, Check Weight System, and Stoppering units.
- HMI Refactoring Updating the operator interface to synchronize alarm handling and recipe management with modified machine capabilities.
- Commissioning Support Performing internal FAT verification and supporting final "Auto-Mode" test runs for all 5 defined bottle formats.
- Software Handover Delivering clean, documented software artifacts (PLC/SCADA projects) for immediate internal maintenance.
in prototype development, the only constant is change. Our role wasn't just coding; it was providing the engineering agility to ensure that when the hardware changed, the machine didn't stop. We delivered functional stability in a fluctuating environment.
Jacek Fischbach
Delivery Executive
Technology used
05
OUTCOME
Despite significant mechanical and electrical interventions during the process, the software was delivered and validated. The project ensured FAT readiness and a complete logic migration, allowing the client to proceed with their commercial roadmap with full documentation and source code.
- FAT Readiness Successfully supported the test run of the whole machine in auto mode.
- Hardware Adaptation 100% logic migration from DC to Servo control for key transport modules.
- Seamless Handover Complete transfer of source code and documentation for the client's team.
- Format Validation 5 distinct bottle formats validated in Auto-Mode across 2 complex units.
06
IMPLEMENTED SOLUTION
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Servo Architecture
Migration from DC motors to high-precision Servo drives within the PLC logic. -
Auto-Mode Testing
Full operational verification for multiple bottle formats to ensure production readiness. -
PLC/HMI Synchronization
A unified interface reflecting real-time hardware status and alarm management.
-
2
Complex prototype units delivered simultaneously
-
5
Distinct bottle formats validated in Auto-Mode
-
100%
Adaptation to new sensor/motor architecture
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