From energy monitoring to full facility control: Scalable FMS solution for CDMO site.

Robust automation, real-time monitoring, and integrated data logging deliver operational reliability and environmental control across production suites.

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Smart Expansion, Seamless Integration. Scalable system powers growth at a US CDMO site.

What began as a straightforward Energy Management System (EMS) implementation evolved into a comprehensive Facility Management System (FMS) for a CDMO facility located on the US northwest coast. Initially focused on energy monitoring, the project expanded to include additional utilities and involving control logic, transforming into a robust solution for a growing production site.

The challenge

The remote location posed some challenges to the customer, who was faced with a shortage of local suppliers and qualified external support. This is where ZETA’s deep technical know-how became a key asset. The project entered implementation after the design phase was completed, requiring the development of detailed specifications and alignment with site-specific quality expectations.

The solution

Standardized, reliable, and future-proof

The customer sought a reliable, standardized system that would minimize validation efforts. After evaluating several automation platforms, they selected Rockwell’s FactoryTalk software and a ControlLogix PLC – an ideal GAMP Category 4 solution offering both simplicity and configurability. ZETA implemented a FactoryTalk View SCADA system using validated process library objects, replacing the previously used Ignition platform, which lacked standardized, pre-qualified libraries. To ensure data integrity under all conditions, ZETA integrated an onboard historian module directly into the PLC. This allows for continuous data logging – even during power outages or network disruptions.

Customer benefits

The new FMS provides enhanced environmental control across the new production suites, including HVAC and utility systems, as well as water quality monitoring. Standardized reporting, real-time monitoring, and automated alerts via email and SMS ensure full visibility and rapid response to out-of-spec conditions – delivering operational reliability and long-term efficiency.

Services

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Gerald Dollberger

Director Business Line Automation

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