Industry in transitionThe design of processes for manufacturing active pharmaceutical ingredients (API) is cost-intensive and time-consuming. Efﬁcient facility design, streamlined project runtimes, shortened development cycles and optimized processes all offer major potential to minimize time to market while keeping productivity high.
The pharmaceutical industry is in transition, faced with increasing competition, reducing prices and patents that are fast reaching their expiry dates. In addition, the industry is also faced with stringent regulations that define quality and processes, while advances in healthcare services are pushing pharmaceutical companies to produce diverse products and develop new therapies. The key to success for the industry is therefore in automation of the manufacturing processes allowing production of different batches for specific patient requirements.
Flexibility and modularity can help manufacturers harmonize active pharmaceutical ingredients (API) more closely with patient requirements or move production to the locations where the medicines are needed, and they also contribute to improved capacity planning based on actual demand – all important factors for sustainable success in the pharmaceutical industry. As a longtime partner to the pharmaceutical industry, Siemens is continually developing its portfolio of products and solutions so that our pharmaceutical customers can benefit from digitalization and strengthen their competitive positions – whether through integrated engineering, simulation, or cloud-based solutions.
We offer innovative software solutions from process development to control and all the way to paperless manufacturing and advanced process analytics.Bhaskar Mandal, Country Division Lead, Process Industries and Drives, Siemens Ltd.
In its state-of-the-art facility in Kurkumbh, the company produces bulk drug APIs (active pharmaceutical ingredients) for a wide range of therapeutic applications – including oncology, anti-diabetic, antiulcer, anti - infective and anti-retroviral (HIV/AIDS) treatments.
Taking a step further in innovation, an initiative was launched by Cipla to drive automation solutions across all API manufacturing facilities for various critical operations like reactor automation, solvent dispensing, crystallizer reactor automation & acquisition of various data, critical to process parameters.
To enable this transition, Cipla shortlisted Process Automation Solutions from Siemens India’s Process Industries and Drives Division. The solution included supply of engineering, and commissioning of automation panels and HMIs suitable for hazardous areas, as well as supply, management, and on-site installation services; laying of cable trays and signal and communications cables; and installation and calibration of field instruments, structural steel, air headers, junction boxes with flameproof enclosures, and many other miscellaneous items.
With DCS-SIMATIC PCS 7, Siemens also partnered Cipla to migrate from Batch manufacturing into Continuous manufacturing by establishing one of the first Flow chemistry based API Production system in India. This helps Cipla to significantly lower floor space, lower the time, reduce wastage, lower energy and utility costs, increase safety and ensure better quality.
SIMATIC PCS7, is a process control system which plays an important role in enabling the Pharma industry in facing upcoming challenges like flexible manufacturing, quality control, regulatory compliance, time to market etc. It also assists in continuous manufacturing, which is the way of the future for faster production and more reliable products through an uninterrupted process. Cipla has employed the use of SIMATIC PCS7 in its manufacturing facility.