OPC UA Application: Pharmaceutical Industry

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⌚Timestamps:
00:00 - Intro
00:47 - Sensors
04:19 - Quality assurance camera
05:16 - Process Analytical Technology sensors
05:58 - OPC-UA Configuration
09:30 - Summary

In this video, we will present how OPC-UA can provide benefits to the pharmaceutical industry.

In the pharmaceutical industry, data is a key component of the manufacturing process.

Manufacturing data is critical to providing proof that good manufacturing practices were followed during the manufacturing process and that the composition and purity of the product meet the required parameters.

How is process data gathered? As with any process, we install sensors in the process to provide critical data from the operation.

We will use a standard oral solids dosage process or OSD process, as an example. OSD processes are ones that take powdered ingredients, mix them, and press the mixture into tablets.

The discussion of specific types of sensors in this type of process, along with detailed OPC-UA functionalities, will help provide an in-depth understanding for those who want to better understand the finer aspects of pharmaceutical pill manufacturing and monitoring.

To do this efficiently, we first need to have several sensors that monitor the manufacturing process.

Resistance Temperature Detectors, called RTDs, or thermocouples, are often chosen for their precision in the narrow temperature bands typical for pharmaceutical processes.
Capacitive pressure sensors are commonly used for monitoring pill compaction in the tablet press.
Magnetic or optical encoders are installed on the product conveyor to monitor belt speed.

Also of importance are optical sensors that can provide visual evidence of product quality. These cameras are the eyes of the operation.

Every pill can be rigorously compared against a standard using sophisticated image processing algorithms. From cracks to color mismatches, nothing slips past.

Process analytical technology (or PAT) can be thought of as a mechanism to design, analyze, and control pharmaceutical manufacturing processes through the measurement of critical process parameters.

An example of a PAT sensor is based on near-infrared technology, which can penetrate through solid mixtures and provide feedback on how well-mixed the solids have become.

The sensors we described each have a specific purpose in the tablet-making process. Each provides data that is important to controlling the process, monitoring the process, and documenting how the product was manufactured.

Sensor data is collected in the manufacturing process by a number of computers, PLCs, and SCADA systems.

In the digital realm, OPC-UA is the linchpin. OPC-UA is a machine-to-machine communication protocol used for industrial automation and provides a platform-independent protocol.

OPC-UA allows the sampling of data at high frequencies, giving it the ability to capture every nuance of the production process in real time.

There are four important characteristics that make OPC-UA so valuable.

First OPC-UA has a configurable data communication rate.
Second, security measures are equally as important as data collection rates.
Third, for operational support, OPC-UA is set up to trigger alarms when data from sensors breach predetermined thresholds. This helps ensure timely intervention by operators.
Finally, OPC-UA provides extensive Historical Data Access support. OPC-UA is used in the process data archive tasks, which is crucial for batch traceability, especially in the event of product recalls.

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