Pharmaceutical SCADA Modernization and Integration

Pharmaceutical SCADA Modernization and Integration

Industry: Life Science
Project Type: SCADA | PLC & HMI | Manufacturing Intelligence | Validation | Project Management

Project Overview

A confidential life sciences manufacturer needed to modernize its production control and data systems to improve operational visibility, data management, and system reliability. Matrix Technologies implemented an Ignition-based SCADA architecture to unify batch and recipe management, streamline operator interactions, and provide advanced alarming, audit trail functionality, and comprehensive reporting.

The new system enables seamless data exchange between SCADA and OEM production equipment, providing a scalable foundation for future manufacturing expansion while supporting pharmaceutical industry validation and compliance requirements.

Scope of Work

Matrix Technologies provided end-to-end SCADA modernization, integration, and validation services. The scope included:

• Requirements refinement and system design documentation
• Ignition 8.1 SCADA configuration and development
• Microsoft SQL Server integration
• HMI graphic enhancements and operator workflow improvements
• Batch and recipe management
• Machine sequencing logic improvements
• Advanced alarming, audit trail functionality, and consolidated reporting
• SCADA integration with OEM production equipment
• Integration testing and Software Factory Acceptance Testing (sFAT)
• On-site deployment and OEM equipment debug testing
• Site Acceptance Testing (SAT)
• Installation, Operational, and Qualification (IOQ) support
• Validation engineering aligned with GAMP 5, 21 CFR Part 11, and validated system design principles
• PLC and automation integration
• Project management and qualification support

Matrix’s multidisciplinary team of automation engineers, validation specialists, and Ignition Gold Certified developers supported the project from requirements development through qualification.

Project Results

The completed SCADA solution improved real-time production visibility, operator workflows, system reliability, and consistency of data capture across the manufacturing process.

The validated Ignition architecture provides integrated batch and recipe management, enhanced alarming and reporting, and reliable communication with OEM equipment. The scalable platform supports compliant data handling and establishes a foundation for future manufacturing expansion.