Stabilizing a Biotech Prototype Amidst Hardware Flux

Stabilizing biotech prototypes amidst hardware flux. Learn how we ensured FAT readiness through PLC/HMI refactoring and Servo drive migration.

Solution

Digital CDMO

Industry

Biotech / Pharma Manufacturing

Scope

Industrial Automation / PLC & HMI Development / Motion Control / Systems Commissioning

Timeframe

~4-5 Months (Base + Extensions)

Complex prototype units delivered simultaneously

Distinct bottle formats validated in Auto-Mode

100%

Adaptation to new sensor/motor architecture

The 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.

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.

The challenge

01

Hardware Instability — Reacting to mid-project migration from DC motors to Servo drives and replacing analog sensors, which required rewriting core logic blocks.
02

Mechanical Constraints — Compensating for mechanical issues, such as drive collisions and design limitations in the transport system, through software adjustments.
03

Scope Fluidity — Addressing emerging R&D discoveries through iterative extensions to the original scope without delaying the final handover.

Our solution

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.

PLC (Codesys / IEC 61131-3)
HMI/SCADA Development
Motion Control (Servo Integration)
Industrial Networks

The 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.

What we implemented

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.