Industrial Automation Magazine India

Today process industries are shifting towards flexible and modular plants

Published on : Tuesday 05-03-2024

Jerome Gnanaprakasam, Global Head – Projects, Engineering, EHS & Sustainability, Dr Reddy's Laboratories.

How process industries have historically automated with sensors, actuators, instrumentation and control in their operation?

25 years ago, particularly in life sciences and similar industries, batch operation process were controlled and recorded manually. Later in the early 2000s, with the introduction of data loggers the critical process parameters were recorded and printed during batch operation. These systems are in compliance to regulatory requirements like FDA. However, all the operations were done manually. As we all know manual operations may have problems related to quality and safety due to complete dependency on humans. With the support of automation industry process controls are being transformed from manual to auto through extensive use of actuators like control valves, sensors and transmitters for flow, level, temperature, pressure, pH, conductivity, etc., by integrating to PLC (programmable logic controllers)/DCS (distributed control systems). This helps organisation to improve efficiency, quality and safety to a great extent. Operational team can visualise and control the process from SCADA systems and quality personal can review for exceptions if any and release the batch immediately. No doubt that this has saved lot of time and efforts.

What are the examples of specific technologies or methods that process industries have used to enhance automation in their operations?

There are various technologies adopted in different industries what best suits them. When it comes to life science industry the quality and safety go hand in hand and it’s a foundation for manufacturing which cannot be compromised. Of course quality and safety is important in all industry whereas in life science it is more stringent and lifeline of the process and non-negotiable as it is directly impacting the patients in a larger way. Process is operated and controlled through batch application as per ISA88 standards hosted in systems like DCS. Also control systems are integrated with Manufacturing Execution System (MES) for paperless e-batch manufacturing report and process control. Safety is yet another critical aspect of the process and ensured through appropriate electrical and instrumentation safety functionalities defined by international standards like ISA, IEC without human intervention. It also helps to meet sustainable goals by optimum use of resource through automated process controls and monitoring in central location with all the dashboards.

What role does digitalisation now play in the transformation of process industries with the convergence of IT/OT (Information Technology/Operational Technology)?

Digitalisation is playing a vital role in the life science industry. Having island of control systems in a factory makes it tough to analyse the process data which requires lot of time, efforts and resources. By connecting all control system network to IT network with central server simplifies the job of process review from anywhere and enabling better data driven decision making and process optimisation. As mentioned MES is also one such integration of OT & IT networks for specific products which eases the production and cross functional team efforts towards reviewing batch reports and for batch release. This helps company to meet regulatory requirements by providing a comprehensive digital record of manufacturing process and quality. However, this approach does have challenges in terms of security, compatibility, additional cost to the company. By having robust security measures and appropriate procedures like user management, patch update, windows check list, backup restore and disaster recovery procedures can overcome these challenges significantly.

How do low code, edge computing, and cloud computing contribute to the flexibility and modularity of plants in the context of process industries?

Today global market is very dynamic and industries should quickly adapt to the changes in order to sustain. I believe with the use of any latest technologies which can give flexibility and modularity always helps industries in many ways to stay updated and respond quickly to such dynamic. In regard to low code, preprogramed modules or functional blocks helps user to develop application quickly by eliminating the need of special coding skills. Platforms like IoT and cloud computing brings lot of value to manufacturing in terms of data analysis, data integrity, reliability, scalability, etc. However, the challenge comes is the right skillset and right implementation which needs to be balanced.

Could you elaborate on the specific benefits that the integration of cutting-edge technologies, such as digital twins and artificial intelligence, bring to process industries?

Digital twins and artificial intelligence (AI) play vital role in process industries in improving capabilities, reliability and decision making. Process models can be created and simulated with various scenarios so that company can gain lot of insight and enable accurate prediction of the process transients. Digital twin supports industries in process and energy optimisation, improve quality, safety and sustainability. On the other hand, AI brings lot of advantages to the manufacturing which eliminates manual efforts by use of robotics, vision systems, etc., and supports operation efficiently. Both digital twins and AI support manufacturing to meet quality, safety and sustainability goals of the organisation. The main challenge lies in quality of execution and right skill set.

How does the trend towards more flexible and modular plants align with broader industry goals, and what are the potential implications for the future of process industries?

Today process industries are shifting towards flexible and modular plants to adapt quickly to dynamic environment. Modular plant supports complex installation and reinstallation with minor reconfiguration based on the product requirements and requires fewer efforts in commissioning. This helps process industries to stay competitive, adapt easily to changing market environment at lower cost. However, creating a flexible and modular plant needs skilled workforce in designing, automation and digitisation.

 

(The views expressed in interviews are personal, not necessarily of the organisations represented.)

Jerome Gnanaprakasam is a Mechanical Engineer, alumni of Harvard Business School having 30 years of industrial experience in leading pharmaceutical operations, capital projects, engineering, safety, environment, ESG & sustainability. He has steered a journey that has enabled the manufacturing operations in to best-in-class organisation through setting up large scale pharmaceutical manufacturing plants & plant operations across the globe in a cross cultural environment. He has driven a step change reduction in Green House Gas (GHG) emission and improvement in energy efficiency. He is a strong proponent of the proactive role companies can play against climate change, when doing business.

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