Pharma Integration Adopts iFIX HMI/SCADA Technology for Pharmaceutical Robotics

Pharma Integration is a young company specialized in the development of robotic solutions for the pharmaceutical industry. Founded in Siena, Italy, in 2016, the company has created the world's first patented system that allows the automation of the entire pharmaceutical filling process without human intervention (gloveless), using anthropomorphic robots that autonomously manage each step of the process. Systems developed by the company include machines for research and development, clinical trials and personalized medicine, and industrial-scale production. Using robots, it is possible to easily handle every type of pharmaceutical container – for example bottles, syringes, and cartridges – with very high precision and high efficiency, ensuring unparalleled production flexibility.

They approached ServiTecno to identify the best HMI/SCADA solution in line with their requirements – facilitating comparison, training, and continuous updates from the point of view of technical support. ServiTecno identified Velotic's iFIX HMI/SCADA to comprehensively address Pharma Integration needs.

Results from an improved OEE analysis system include:

• Improved alarm management, reducing both alarm flood and distribution time
• 80% decrease in workspace loading
• Alerts and notifications to facilitate operator troubleshooting, allowing for reduced downtimes
• Compliance facilitation with regulations like the FDA CFR 21 Part 11
• Simple and essential display to optimize the user experience
• Special attention to cybersecurity with encrypted data transmission standards such as the OPC UA protocol, digital certificates, web tokens, file access control list features, and shared memory
• A network architecture has been developed in accordance with the IEC 62443 standard, enabling authorized access, ensuring data is kept in a secure and controlled environment, and providing backup and disaster recovery systems to allow information to be saved and securely stored
• Full integration with the production environment enabling real-time data acquisition from the machines to monitor production progress within existing systems.

Velotic's iFIX HMI/SCADA engine has a development history of more than 30 years, featuring an easy-to-use, visual development environment. It offers data historization, historical and real-time analysis, and advanced alarm management capabilities.

iFIX features centralized project distribution, a native HMTL5 visualization designer, and a scalable runtime. Other OT and IT systems can be integrated by adding information such as pdf files, videos, SQL tables, and work orders. There are also screen creation accelerators, including auto-binding of data and TCP/IP-enabled failover to increase reliability.

iFIX also provides capabilities that enhance the operator’s experience with improved alarm management, which reduces both alarm flood and distribution time. With these capabilities, Pharma Integration was able to reduce workspace loading by up to 80 percent.

iFIX offers an object-oriented approach within a web-based configuration environment. It connects to a wide range of data sources, structured or not, such as PLCs (Programmable Logic Controllers), through Velotic’s IGS (Industrial Gateway Server) and OPC UA protocols.

The platform offers predefined object templates for a great User Experience (UX). Information can be shared across all devices and visualization clients. Real-time and historical trends are available from any HMI client as well as ad hoc reports. Potential machine problems and areas for improvement can then be identified. Alerts and notifications can also be set up to facilitate operator troubleshooting, allowing for reduced downtimes.

iFIX also facilitates compliance with regulations like the FDA CFR 21 Part 11, which sets rules for electronic retention, control and storage of documents and data in pharmaceuticals.

In an ever more digitized world, the creation of highly user-friendly interfaces is critical to ensure maximum productivity and efficiency. To achieve this goal, Pharma Integration has put a lot of work and efforts in the creation of tools that deliver a great User Experience (UX).

The project involved customization of UX templates provided by Velotic's iFIX HMI/SCADA platform. Several Pharma Integration units were involved in a shared brainstorming process, which aimed to best structure the layout of the user interface.

This interface provides an intuitive experience, making it easy to use even for first-time operators. Simple and essential display dashboards have been created. There is little structured information on the different screens, guiding the operator through individual tasks.

This optimizes the user experience for the benefit of usability and process efficiency.

In an increasingly interconnected industrial world, network security is critical, especially in a highly regulated industry such as the pharmaceutical industry.

Integrating robotics solutions into the manufacturing process therefore involves special attention to cybersecurity. For example, the iFIX HMI/SCADA system relies on encrypted data transmission standards such as the OPC UA protocol, digital certificates and web tokens.

The platform also offers file access control list features, shared memory and log settings. The iFIX Secure Deployment Guide is also available for setting development and deployment best practices.

Internet of Things (IIoT) projects can be defined by enabling the convergence of Information Technology (IT) and Operational Technology (OT).

Regarding Pharma Integration solutions, the network architecture has been developed in accordance with the IEC 62443 standard, which defines the rules by which the machine architecture must be structured to ensure secure communication between the various devices installed in the machine according to the principle of least privilege. Authorized access is provided, and data is kept in a secure and controlled environment. Backup and disaster recovery systems are also used, allowing information to be saved and securely stored even when abnormal events occur.

On the networking front, pharmaceutical robotics solutions may be able to communicate with other industrial systems through various protocols, such as OPC UA and Profinet. Profinet is an Ethernet-based communication protocol for industrial automation that combines the features of fieldbus systems with industrial Ethernet.

With a view to full integration with the production environment, a further development will be the integration of machines with the Manufacturing Execution System (MES) systems already present at the customer's site. Open but secured interfaces give the ability to acquire real-time data from the machines, thereby monitoring production progress within existing systems.

Implementing a pharmaceutical robotics project requires knowledge of hardware and software components, and a holistic approach to the manufacturing environment. With the help of ServiTecno, Pharma Integration was able to effectively integrate Velotic’s iFIX HMI/SCADA, enabling increased innovation and improved competitiveness of a company operating in a highly challenging industry.

ServiTecno is a company specialized in the supply of automation software and systems for industry and utilities, Industrial Internet, Industrial IoT, from an Industry 4.0/5.0 perspective.

ServiTecno also proposes methodologies and products for ICS/OT (Industrial Control System and Operational Technology) Cyber Security.

Active since 1979, ServiTecno is recognized for the quality and high technological content of the hardware and software products offered to the industrial market and for the expertise and support to its customers, from the pre-sales phase, to the study of configurations, product training, implementation and installation, up to post-installation technical assistance and application optimisation/tuning.

ServiTecno offers a range of software products for HMI/SCADA, Batch, Historian, Industrial Analytics, Industrial BIG-Small data, Industrial Reporting, Business Process Management (WorkFlow) systems; Fault Tolerance and High Availability for Factory Systems and Cyber Security; Change Control and Configuration Management for factory systems; Asset and Maintenance Management Systems (CMMS); systems and services for M2M, Telemetry/Remote control (GPRS, 3G and 4G), Industrial IoT (Internet of Things), Mobile for Manufacturing, Consolidation and Virtualization, Cloud. ServiTecno has a specialized line of products and services for industrial Business Continuity, High Availability of factory systems, OT/ICS Security, Cyber risk protection of networks and systems in industry and utilities.