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Case Studies

Deploying a global standard for weigh and dispense

Zenith worked with the client to deploy the solution for the first time at one of its key manufacturing sites in the U.S. The project was driven by the fact that the site was moving from a legacy ERP to a new standard SAP system. This move rendered the legacy weigh and dispense system and custom interface as obsolete.

Antibiotic Production Facility Benefits from Modernisation

One of the world’s largest pharmaceutical companies, needed to modernise its antibiotic production in the South East, USA. Since the antibiotic is no longer under patent, they needed to bring the new facility on line while rigorously controlling costs in order to successfully compete with generic drug manufacturers.

Justifying the Business Case for Implementing an MES System

Our client specialises in producing pharmaceutical products for eyes, medical devices, lasers and eye wear. Since witnessing steady growth and an acquisition the company wanted to move towards a company-wide implementation of SAP across all of it’s 21 sites in the USA, Europe and Asia.

Zenith put together a team of experts to provide a complete and impartial evaluation of the potential benefits of MES, with recommendations for solutions and a comprehensive implementation plan.

MES Centre of Excellence brings Standardisation and Productivity Improvements

A global pharmaceutical company with sites worldwide has a requirement to standardise their Manufacturing Execution Systems across four sites. In order to achieve this they wanted to create an MES Centre of Excellence (CoE) that would sit above all sites and provide leadership, best practices, research, support and training. The CoE needed to be tailored to the customer’s needs and flexible enough to work within a disparate configuration of the same MES platform.

New SCADA System Implementation and Network for Major Pharmaceutical Facility

Zenith experts designed and installed a complete SCADA (Supervisory control and data acquisition) system for the utilities at the plant. This included a data historian and an alarm system together with a highly resilient Hirschmann fibre optic data network linking the various production units.

Control System Upgrade from RS3 to DeltaV for Global Biotech Company

This case study is for one of the largest global biotech companies in the world, focused on the development and delivery of transformative therapies. With its main HQ in the US, the customer has been in operation for over 30 years and specialised in the class of rare genetic diseases. They approached Zenith Technologies with a requirement to migrate the existing Rosemount (RS3) control system within its manufacturing plant at Allston, Massachusetts to a more modern and efficient solution.

Serialization Project Rolled Out Across 20 Sites Worldwide for Multi-National Pharmaceutical Company

The Zenith Serialisation team began by working as a part of the client’s design team to develop an enterprise solution that would deliver serialisation functionality to its entire network. Once the design stage was completed, the team concentrated on the specifics by creating a test lab within one of the client’s facilities to validate the chosen serialisation solutions.

Standardising Manufacturing Across Multiple Plants With Managed Service Solution

A world leading pharmaceutical company with multiple production facilities in Ireland wanted to standardise manufacturing systems and work practices across multiple plants whilst achieving cost reductions and improvements in both efficiency and resilience.

Site Expansion Project to Increase Capacity for Top 10 Pharmaceutical Company

This customer manufacturers biopharmaceuticals and vaccines, and currently has 1,000 full time employees on site. The site in question is one of the largest Biotech Operating Units implementing state-of-the-art technology, cutting edge thinking and production expertise. As part of a reorganisation of its manufacturing strategy, the company launched large expansion project to add manufacturing capacity and transfer existing products to another facility.

Automation Solutions for Dryers and Spray Dryers

Zenith have a particular expertise in setting up and commissioning complicated interactive spray drying equipment. The list below provides a sample of projects that have been successfully completed for various companies and technologies.

Automation of Two Production Buildings for Asian Pharmaceutical Company

The following two projects were completed by Zenith for a Client in Singapore. Both projects consisted of DCS platform upgrades for two separate Production buildings on the same facility. ZT’s scope for both projects ran from the FEED right through to handover to manufacturing. On average, the scope of the PB2 Project was 130% of the size of PB 1(In terms of I/O, Software components, processing equipment). Download for more information.

DCS Migration Project on Downstream Process for Bio-Pharmaceutical Company

Zenith was awarded the Functional Specification authoring and development of the downstream portion of a 8,000 I/O Provox to DeltaV migration. The facility was to be converted from a Cell Culture facility to Microbial Fermentation and all equipment was replaced to accommodate increased capacity. Areas under Zenith’s responsibility were Recovery, Buffer, Purification and Formulation which included Centrifuge, Chromatography, UF/DF, Inline Dilution and various vessel unit operations. In order to meet the schedule deadlines an integrated commissioning and validation approach was used requiring the leveraging of software FATs.