Pharmaceuticals: Boiler Operation & Data logging

Boiler: Pharmaceutical industry boilers are a critical component to any processing plant. Whether the steam boiler is used in the process of medicinal drying, sterilizing, and purifying; boilers used in the pharma industry must be extremely precise, which means it has high temperature control demands Most pharmaceutical firms choose high pressure steam boilers due to the simplicity and efficiency of the system. At the same time, high pressure steam boilers can be used for direct heating as well as indirect heating. All of these reasons are why high pressure steam boilers are the premier solution for pharmaceutical process heating.

Case Study Pharmaceuticals
Applicable Industry Pharmaceuticals
Use Case Boiler Operation & Data logging
Interfaces PLC, SCADA System, Sensor, field instruments with cabling
Customer Leading Captive Energy Sectors
Data Exchanged Data logging in Excel format
Technology PLC with SCADA
System PLC Automation system
Challenges:
  • old relay base control panel
  • Low efficiency
  • Frequent shutdown due to failure of components
  • Long repair cycle becouse of old tech instrumentation
  • Difficult to expansion
  • Requires a lot of switchboard space
  • Installation is very labor intensive
  • Trouble shooting is extremely difficult
  • Modifications to the control functionality are complicated and seriously tedious.
Solution:

We as VACPL provided efficient and end to end solution of PLC based control panel and which is helping customer in below ways. installation time is greatly reduced with PLC control systems due to the reduced amount of hard wiring required. In other words, we only need to hard wire the input and output devices. The control logic is implemented using software not hard wired relays. Modifications to the control logic can easily be done using software to modify the ladder logic program rather than hardware and wiring modifications that would normally be the case with relay logic control. The same PLC can be used for a wide range of control system applications.

Impact 1
  • Batch time reduced by 15%, hence increase in productivity.
  • Precise evaporation ratio.
  • No loss of energy since steam is not required to be released through bypass valve Improvement in product quality
Impact 2
  • Efficiency improvement.
  • Down time reduction.
  • Proactive maintenance.
  • Cost reduction of overall maintenance.