Automation of a complex laboratory test stand for process development in the pharmaceutical industry
The Initial situation at the customer
A company from the pharmaceutical industry operated a complex laboratory test bench for the development and characterization of viscous media. The test stand consisted of a large number of different components and peripherals - including scales, cooling systems, pressure regulators, volume flow sensors, torque measurement, a motor with frequency converter and several valves.
The system had grown over time and was mainly operated manually. Different stand-alone solutions, a lack of automation and inconsistent communication between the devices made reproducible operation considerably more difficult. Tests could only be carried out with a great deal of manpower and there was no consistent data acquisition.
The customer's goal was a centralized, automated test bench control system that enables reproducible test conditions, safe process control and complete data acquisition - while at the same time being easy to operate for the laboratory staff.
Our solution
Following a detailed analysis on site, we developed a modular automation concept based on our own measurement and control technology. The core of the solution consisted of
- The modular automation system Expert Logger 400
- The central control, visualization and data acquisition software Delphin Data Center
- Individually developed device drivers for the connected peripherals
Special focus was placed on:
- Standardized integration of all measured and control variables
- Open interfaces for future extensions
- Stable, industrial-grade communication
- A clearly structured and intuitive user interface
Implementation & commissioning
The implementation took place in several commissioning phases directly on the test stand. This showed that the technical reality on site differed in many details from the original assumptions. Missing interface information, deviating plug connectors and device configurations that were not clearly specified required a high degree of engineering expertise, flexibility and practical troubleshooting.
In the course of implementation, among other things:
- All sensors and actuators centrally connected via the Expert Logger 400 system
- Serial interfaces, analog signals and digital inputs/outputs neatly standardized
- Several closed control loops for pressure, temperature and speed realized
- The entire test procedure is automated on the software side
- Intelligent switching between manual and automatic mode implemented
At the same time, the process engineering structure of the system was optimized together with the customer so that the control technology was also given mechanically stable framework conditions.
The result
The previously manually operated test stand was successfully converted into a fully automated laboratory system. Today, the system enables:
- Reproducible test sequences
- Automated control of pressure, temperature, flow rate and actuator
- Central visualization of all process data
- Seamless measurement data acquisition for process validation
- Significantly reduced operating errors
- High operational reliability:
- Future-proof expandability thanks to the modular system concept
The plant now serves as a central development platform for the subsequent transfer of the knowledge gained to large-scale production processes.
Sustainable added value
Even after the project was completed, the lasting benefits of the solution were demonstrated several times in practice:
After hardware changes and a system relocation, the entire application could be restored quickly and completely thanks to the structured data storage and system architecture. In addition, the communication of individual devices was further optimized, ensuring even more stable and faster process management today.
This project is an example of how a modern, powerful and future-proof laboratory test stand control system can be created from a historically grown, manually operated test facility through the targeted use of modular automation technology, individual driver development and end-to-end system integration.