Complete control

The system also has advantages when a new product is launched or a recipe changed. Previously, this would have meant a period of shutdown while new operator stations were installed; now, the mobile ones can simply be wheeled to different areas to keep an eye on the important process steps. ’Because of the wireless network, we do not need to systematically invest in new control stations, even if the production of new products requires a change to the plant equipment or layout,’ said Novartis automation expert Patrick Borschert.

The new systems have also helped Novartis to diversify production at Huningue. As well as the single-chain Xolair molecule, it is now able to produce more complex, multi-chain molecules, such as monoclonal antibodies and immunosuppressives.

Keeping operators in touch with the process is vital, wherever their workstations are, and the key to this is workable human-machine interfaces (HMIs); these are standard in larger facilities, but still not widespread in smaller operations. This was recently a problem for Nicholl Food Packaging, which makes foil containers and disposable packaging for the catering industry. Based in Cannock, Staffordshire, the company found that the HMIs on its electrically controlled presses were failing, probably because of the machinery’s vibration.