Pharma Automation

November 4, 2020 11:42 am

An analysis on why it’s important to consider the benefits of the latest automation and robotics technologies in the pharmaceutical industry.
– Subhajit Roy, Executive Editor

The pharmaceutical industry is increasingly making use of robotics and robotics to automate specific processes in drug development – from filling, inspection and packaging to drug screening, anti-counterfeiting and manufacturing. The advantages include greater speed and accuracy, more flexibility and increased reliability.

Commenting on how automation and robotics benefits pharmaceutical industry, Ninad Deshpande, Head – Marketing & Corporate Communication, B&R Industrial Automation Pvt. Ltd., said, “Pharmaceutical companies are continuously looking for new ways to increase efficient production leading to increased reliance on automation and robotics. Everyone is already aware of the immense benefits automation, robotics and digitisation brings to production facilities. These include but not limited to hygienic handling, high cleanliness, improved accuracy, precision, easier maintenance and diagnostics, higher productivity, efficiency, optimised processes, secure data handling, vertical and horizontal connectivity on factory floor etc. On the other hand, in R&D or QC- QA laboratories, developing new drugs or performing some tests, usually involves repetitive tasks such as blending, stirring, titration, moving fluids and test tubes. Robots are the perfect fit as they provide a high level of accuracy and consistency. By using robots in such menial tasks, scientist can focus on important activities as new drug development and research.”

Robots can work on certain tasks 24/7, enabling humans to avoid hazardous zones or tedious repetitive tasks. Moreover, it helps in eliminating human error, increasing accuracy, repeatability and reproducibility and in case of cleanrooms, removing potential causes of contamination by human contact.

With Machine-Centric Robotics, B&R now offers ABB robots as an integral part of its automation system. Customers benefit from unprecedented precision in synchronisation between robotics and machine control. Merging robotics and machine control into one unified architecture enables manufacturers to embrace the trend of mass customisation and optimise their batch-size-one processes. This not only reduces machine footprint but improves machine performance and speed. Machine builders will get their robots and machine control system from a single source needing only one controller and one engineering system for development, diagnostics and maintenance. This lowers the threshold for those looking to implement robotics. In its recent announcement, ABB has enhanced its portfolio of high-speed industrial robots with acquisition of Codian Robotics, which builds on its industry-leading food and beverage, pharmaceutical and logistics portfolio. Codian Robotics is a provider of delta robots, which are used primarily for high-precision pick and place applications. Codian Robotics’ offering includes a hygienic design line, ideal for hygiene-sensitive industries including food and beverage and pharmaceuticals. Machine builders in the pharmaceutical industry definitely will be benefited from the vast product range in B&Rs offering right from Machine-Centric Robotics, APOCOStrak to integrated robots and vision.

Ruchi Mathur, Head – Commercial Marketing, Rockwell Automation India Pvt. Ltd. opines, “We work with top biotech, pharma, and device manufacturers to make their facility of the future a reality today. They can embrace the same digitised automation, IIoT connectivity, single-use equipment, and flexibility as their next competitive advantage.”

These technologies enable The Connected Enterprise, maximise the performance of their business, and help them to:
• Speed time-to-market with flexible, modular operations
• Drive compliance and boost productivity with in-process data and analytics
• Make better decisions and manage costs with real-time actionable insights
• Gain continuity with an OT approach to cybersecurity.

Through The Connected Enterprise, Rockwell Automation helps manufacturers capitalise on the promise of a more connected world. Manufacturers realise this promise in the form of a more agile response to changing consumer preferences, accelerated product introductions, lower cost of ownership, improved asset utilisation, and enterprise risk management.

Rockwell Automation’s expertise in pharma automation
The most successful organisations are rigorous about their processes and the ability to understand pharma manufacturing operations, process control, validation, and quality improvement. “By applying advanced technologies and improvements in manufacturing efficiency, we can help you convert this effort into higher-quality products, less rework, increased profits, and a distinct competitive advantage,” said Ruchi.

Intense competition, higher production requirements, and a strict regulatory environment place pressure on pharma manufacturers to optimise production. The pharmaceutical industry is facing significant challenges. Speed to market is more important than ever to reach new emerging markets, to compete with generics, and to get the most out of products before their patents expire.

It is important to harness the power of an integrated control and information system to build a connected enterprise. The ability to attain organisation-wide connectivity and visibility helps to align local operations with global requirements and to improve efficiencies across plants.

Ruchi adds, “We have extensive experience in providing integrated automation and information solutions also provide real-time access and extended enterprise visibility to vital manufacturing data. They can then implement business process improvements and increase access to real-time production information. They can also improve supply chain integration across their pharma facility.”

B&R’s expertise in pharma automation
Pharmaceutical machines and factories are already highly automated and adhering to various compliances. Today, they are also digitising various operation and processes and further looking at optimisation possibilities for improving bottom lines, efficiency and productivity. With the easy to adopt technologies, the barriers are fading. These new technologies are actual game changers and lead to higher profitability. B&R offers machine builders and factories complete hardware and software solutions, comprehensive service and hard-earned expertise in automation. Further, B&R enables automation and digitalisation of machines and lines, thus helping machine builders and factories remain competitive in this new environment. B&R mapp Technology handles recurring programming tasks by providing preconfigured blocks – basic functions – that are easy to use and that have already been extensively tested. Programmers can then concentrate on their main task of implementing machine processes in the application software. These modular software blocks simplify the development of new programs and reduce the development time for new machines and systems by an average of 67%, informs Ninad.

In addition, pharma industry needs to log operations performed by users without the risk of being tampered. According to Ninad, “With our mapp Technology, we provide a quick and easy ways to implement and customise audit trails. Machine builders thus, obtain various benefits and comply with FDA CFR 21 Part 11 using a controller instead of using a dedicated SCADA system. Machine builders and factory operators benefit from maximum security without altering anything in the control system.”

With B&R solutions, machine builders achieve accelerated development and reduce investment risk for applications subject to the FDA’s Title 21 CFR Part 11 requirements. The ability to retrace actions performed on a machine can also be of great service to its manufacturer in the event of warranty claims.

“With our ACOPOStrak, Machine-Centric Robotics and vision, machine builders not only benefit from enhanced machine design and productivity but also offer their customers an integrated automation system, drastically reducing machine footprint,” Ninad adds.

In addition, B&R enables pharma industry to improve lifecycle management, condition-based predictive maintenance, process data acquisition, long-term archiving, secure remote maintenance and diagnostics, edge computing and open connectivity possibilities. Apart from customisation and reduced development times, in order to fulfill huge demand of machine uptime, B&R has adopted express support and services activities.

Some of the applications, B&R has worked on in India for leading pharmaceutical companies based in Mumbai and Pune are blister packaging, capsule filling, tableting, tablet coating, primary and secondary packaging, cartoning, check weighers, tube filling, capping, labelling amongst others. The company has been supporting pharmaceutical machine builders to build automated machines with advanced automation technologies for over a decade.

Pharma company uses Rockwell’s serialisation solution
Background
One of Asia’s largest biopharmaceutical companies is driven by the vision to improve access to high-quality, life-saving biotherapeutics. They needed a turnkey serialisation solution with complete track and trace technology to secure and authenticate products across its supply chain. The right investment in the right technology would enable this company to more quickly commission and transport products to those in need.

Challenge
More quickly commission life-saving biotherapeutics line, meet current and evolving regulatory standards.

Solution
This company produces thousands of packages a day and required a solution that could be implemented with little disruption to its production. Rockwell Automation delivered a serialisation solution that addresses challenges across the spectrum, from automation to MES and ERP to the cloud. Solutions include:
• FactoryTalk ProductionCentre
• Rockwell Software PharmaSuite
• Integrated Architecture – Helps minimise interoperability challenge with dedicated control network
• Logix-based unit controller – Integrates easily into existing systems with preconfigured order channels.

Results
• Reduced packaging rejection from 7% to less than 1%
• Reduced cycle time by 18-20 days
• Reduced work in process by 5%.

Quotes
We work with top biotech, pharma, and device manufacturers to make their facility of the future a reality today.
Ruchi Mathur, Head – Commercial Marketing, Rockwell Automation India

Pharmaceutical companies are continuously looking for new ways to increase efficient production leading to increased reliance on automation and robotics.
Ninad Deshpande, Head – Marketing & Corporate Communication, B&R Industrial Automation