R&D Center Finds Room for Condition Monitoring

A compact automation offering allows Boehringer Ingelheim to bring condition monitoring into the mix of active pharmaceutical ingredient production at its new R&D center.

The valve terminal platform resides entirely in the control cabinets and allows Boehringer Ingelheim to position it outside of the API reactor rooms.
The valve terminal platform resides entirely in the control cabinets and allows Boehringer Ingelheim to position it outside of the API reactor rooms.

Though some industries and companies lag in R&D, the pharmaceutical industry isn’t one of them. New R&D is a vital ingredient for company longevity in this industry, along with manufacturing innovation.

Recently, the pharmaceutical giant Boehringer Ingelheim built a new research center that produces small batches of active pharmaceutical ingredients (APIs) for clinical studies. The 29,000 sq ft R&D center in Biberach, Germany, employs a condition monitoring approach for inert gases being added to process tanks at variable levels of pressure.

The production of active ingredients involves flammable solvents with reactors, centrifuges and dry cabinets. Though many different gases are used, nitrogen and argon play a large role at the research facility.

Before the new research center was built, the regulation of inert gases was a manual operation. Operators also manually adjusted regulating pneumatic valves and relied completely on a closed-loop control system. After meeting with Festo, Boehringer Ingelheim determined it wanted more automation and condition monitoring for this unique pharmaceutical ingredient application.

According to Boehringer Ingelheim, the company “wanted to have higher flexibility—due to many (quick) changeovers—and overall better monitoring of this process.” The research center produces many small batches for clinical studies, with reactors capable up to 1 cubic meter or 1,000 L.

Though it was paying for production flexibility, the pharma giant wasn’t overly concerned with a quick return on investment due to lower device costs, quick commissioning and better operational efficiencies, according to Festo.

The previous clinical production design included three pressure levels to regulate argon and nitrogen, each with its own piping network, control valves and flowmeters. The new setup now uses Festo’s VPPM proportional pressure regulators that integrate into an MPA valve terminal and connect to a CPX automation platform. While these regulators offer multi-sensor control via two pressure sensors, this open-loop control platform communicates with a Siemens PCS-7 plant system for set-point values.

Researched List: Blister Machines for Life Sciences
Need a blister machine for life sciences packaging? Our curated list features companies serving pharmaceutical, medical device, nutraceutical, and cosmetic industries. Download to access company names, locations, machine specifications, descriptions, and more.
Download Now
Researched List: Blister Machines for Life Sciences
FDA warning letters surge - is your team prepared?
New guide reveals expert strategies to prevent regulatory issues and respond effectively to FDA enforcement actions in pharmaceutical and medical device manufacturing.
Read More
FDA warning letters surge - is your team prepared?