Pharmaceutical Production Facility – FTBatch Control System Modernization



A pharmaceutical manufacturer (Client) in the Twin Cities, MN area needed to modernize their existing FactoryTalk Batch Control System.   


The project involved over 65 units, 500 recipes, 300 tank-to-tank transfer routes and 25 ControlLogix PLCs, impacting virtually the entire production scope of the Client’s facility.  The Client needed a trusted system integrator to execute this project to ensure minimal impacts on production as well as successful startup of the modernized system.


Excel Engineering contracted directly with the Client and worked with engineering, operations and validation personnel directly to ensure a successful integration effort.  Services included

  • Functional and Detail Specification development
  • PLC and HMI design and programming
  • IQ/OQ generation and execution
  • Major systems included Media Preparation & Hold, BioReactors, Centrifugation, Buffer Preparation & Hold, Chromatography, Viral Filtration, Ultra Filtration, CIP and SIP


Utilizing module design based on PlantPAx objects and phase design implemented with PhaseManager, Excel was able to successfully upgrade the Client’s facility according to the overall project scope and schedule, allowing the Client to achieve their modernization needs while minimizing impact on the production schedule. 

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