Operational Core

Deep expertise gained from the world's top life sciences companies

Strategically headquartered in Pune, India, our team of 20 experienced engineers implements GAMP 5 and S88 validation workflows globally.

PLC Systems

Allen Bradley, Siemens, Mitsubishi, Schneider, Omron, Koyo controllers.

SCADA / HMI

Ignition, WinCC, FT View SE/ME, RSView32, ViewJet, C-More applications.

Network Protocols

Profibus, DeviceNet, ControlNet, Modbus, Ethernet TCP/IP.

Validation (V-Model)

URS, FDS, HDS, SDS, IQ, OQ protocols, standard test procedures.

S88 Batch Standard

Modular Recipe & Control Engineering

We deploy ISA-S88 batch control standards to guarantee code reusability, plant consistency, and streamlined regulatory validation cycles.

Physical Model

• Enterprise & Site
• Process Cells
• Units / Equipment
• Control Modules

Procedural Model

• Recipes
• Unit Procedures
• Operations
• Control Phases

Operational Value Generated: Reduces validation complexity by segmenting control modules from dynamic batch process operations.

GMP Compliance Validation

Verification & Validation Life Cycle

Our turnkey projects follow the high-performance GAMP 5 V-model mapping software, hardware configurations directly against initial user and functional design specifications.

URS & FDS Specifications ◀ Verifies ▶ Operational Qualification (OQ)

Hardware & Software Design ◀ Verifies ▶ Installation Qualification (IQ)

Software Development ◀ Testing ▶ Factory / Site Acceptance Tests

Standardized Deliverables: All code is pre-validated with module-level unit testing and rigorous verification reports.

Pharmaceutical Engineering Showcases

Select any portal below to interact with live software and telemetry simulators.

EMCURE (INDIA) WINCC HMI

VHP Generator HMI System

Siemens S7-300 automation with secure 21 CFR Part 11 Audit Trail tracking and analytical calibration.

Open Demonstration →

DR. REDDY'S (INDIA) S88 BATCH

Bioreactor Vessel Automation

Wireless networks integrating mobile Microfluidizer, Homogenizer, and Pool Tanks with central control registers.

Open Demonstration →

PHARMAFORCE (USA) CONTROLLOGIX

Critical Utilities & Isolators

Industrial-grade chilled water distribution, purified water level metrics, and automated isolator cleaning.

Open Demonstration →

Universal Integration Matrix

Automation Platforms & Software Frameworks

Certified operational expertise across leading control hardware, SCADA hosts, and MES systems.

Enterprise SCADA Solutions

We design robust central gateways, high-speed transactional databases, custom analytical trend lines, and Part 11 compliant configurations.

Ignition (Inductive Automation) Perspective & Vision architectures, SQL database bridges, central Python scripts.

Siemens WinCC WinCC Unified, Classic, and Portal environments. Native memory mapping protocols.

FactoryTalk View SE (Rockwell) Distributed server architectures, FactoryTalk Directory services, and VBA macro optimization.

Programmable Logic Controllers

Engineering deterministic logic, PID control loops, high-density digital routing, and modular safety systems.

Siemens Simatic Stack S7-1500, S7-1200, and S7-300/400 platforms configured via TIA Portal or Step 7.

Allen Bradley Logix Studio 5000 Logix Designer for ControlLogix, CompactLogix, and GuardLogix networks.

Mitsubishi & Omron Multi-axis drive synchronizations, EtherCAT network layout, and custom motion rules.

Manufacturing Execution Systems

Seamless integration bridging floor-level manufacturing networks with ERP systems to streamline operational performance.

Sepasoft Integration Deploying native OEE, recipe, and batch modules directly into client Ignition gateways.

Overall Equipment Effectiveness Automated cell downtime tracking, performance indexes, and visual analytics.

Traceability & SPC Material lot parsing, raw-material genealogy tracking, and live SPC metrics.

Enterprise Stack Architect Simulator

Combine varied platforms below to simulate live tag polling, database syncs, and MES performance loops.

1. Select Control Platform (PLC)

2. Select SCADA Engine

3. Select MES Module

ARCHITECTURE MODEL MIMIC

STATE: ACTIVE MODEL POLLING

Level 3: Enterprise MES Sepasoft OEE

Database Sync: ACTIVE

KPI Calculated: OEE: 84.5%

Level 2: Supervisory SCADA Ignition Gateway

Active Tag Count: 12,450 Tags

Hist. Rate: 1.0 sec

Level 1: Field Controls (PLC) Siemens S7-1500

Bus Network: Profinet IP

Scan Cycle: 12.4 ms

Pions turn-key deployment integrates hardware drivers, maps parameters, and guarantees FDA electronic signatures compliance.

VHP Generator Systems / Emcure Pharmaceuticals Ltd.

Vaporized Hydrogen Peroxide Generator Automation

PLC: Siemens S7-315-2 DP SCADA: WinCC 7.4 SP1 Comm: MPI Protocol

Delivered Automation Scope

For sterilization operations, Pions Technologies engineered the complete functional specifications (FDS) and logic integration for the Vaporized Hydrogen Peroxide (VHP) Generator system. This system incorporates precision environmental monitoring and critical parameter recording necessary for complete cleanroom decontamination.

21 CFR Part 11 Electronic Records (Audit Trail)
Custom Automated Crystal Batch Reports
In-Situ Calibration of Core RTD Sensors

Topology & Functional System Architecture

Siemens S7-315 PLC Main Processor

MPI Comm.

WinCC SCADA IPC Operator Panel

P&ID Engine Static advance libraries with dynamic component animations.

Audit Trail Log Timestamped tracking of button events & setpoint values.

Batch Trends RTD parameters history with live-updating query curves.

Interactive Demonstration Panel

Emcure PLC LINK: ACTIVE

SCREEN ID: CYCLE PARAMETERS#0

USER: sup1

TIME: 11/22/2018 08:32:04 PM

ALARM 11/22/2018 07:53:39 PM - OPERATOR MANUAL ABORT DETECTED IN LAST RUN - RESET COMPLETED

VHP Telemetry Points

CYCLE AIRFLOW:

68.0 m³/hr

AIR INLET RH:

0.0 %RH

AIR INLET TEMP:

92.3 °F

VAPORIZER TEMP:

220.2 °F

Current Cycle Status

CURRENT PHASE: DECONTAMINATION RUNNING

RESERVOIR WEIGHT: 855 g

INJECTION RATE: 3.0 g/m

TIME REMAINING: 06:14 Min.

Aeration Cycle Progress 45%

RTD Calibration Coefficients & Intercept Matrices

SENSOR TAG	SLOPE (m)	INTERCEPT (c)	CURRENT VALUE	STATUS
VAP. RTD 2 (Vaporizer Temp)	1.0024	-0.124	220.2 °F	CALIBRATED
PRE-H RTD 4 (Pre-Heater)	0.9985	0.045	194.0 °F	CALIBRATED
AIR INLET RTD 5 (Air Inlet)	1.0000	0.000	92.3 °F	FACTORY
GEN HOUS. RTD 6 (Housing Temp)	1.0112	-0.552	120.2 °F	CALIBRATED

21 CFR Part 11 Electronic Event History

● SECURE AUDIT MODULE ACTIVE

Date & Time	Action Trigger	User ID	Description Details
11/22/2018 08:33:09 PM	BATCH_COMPLETED	SYSTEM	VHP run cycle: VHP0031121 terminated successfully. Reports queued.
11/22/2018 08:07:18 PM	CYCLE_START	sup1	Sterilization batch started with recipe standard decontam_03.
11/22/2018 07:44:12 PM	CALIBRATION_SAVE	cal_eng2	RTD 2 slope recalibrated from 1.000 to 1.0024. Offset stored.

Automated Batch Report Generation

Simulate the direct output of compliant GMP verification reporting files.

Emcure EMCURE PHARMACEUTICALS LTD.

VHP GENERATOR BATCH REPORT ID: VHP-GEN-003
Compiled On: 11/22/2018 08:33:09 PM

Cycle ID: VHP0031121

Equipment ID: VHP003

Batch Number: VHP14112018

Cycle Start: 2018-11-22 08:07:18 PM

Cycle End: 2018-11-22 08:31:16 PM

User Session: sup1

Operational Phase Set Parameters

SR.	PHASE KEY PARAMETERS	SET VALUE	LIMIT UNIT
1	Dehumidification Airflow	68.0	m³/hr
2	Conditioning H2O2 Injection Rate	4.0	g/m
3	Decontamination Airflow	64.6	m³/hr
4	Aeration Internal Target Timer	03:00	Min.

Checked By Operation Team

Sign & Date 11/22/2018

Verified By Quality Assurance

Sign & Date 11/22/2018

S88 Portable Skids / Dr. Reddy's Laboratories

Portable Formulation Equipment Integration

PLC: Central Siemens S7-1214C SCADA: WinCC Explorer Net: Scalance Industrial Wireless

Portable Skid Integration & Wireless S88 Control

For Dr. Reddy's Laboratories, Pions Technologies engineered the system logic and networks required to integrate highly mobile, portable equipment skids into a streamlined production environment.

Integrated Skids: High-performance mobile Microfluidizer, Homogenizer, and double Product Pool Tanks.

Centralized PLC Control: Equipment operates as decentralized field nodes reporting wirelessly via Siemens Scalance radio links.

S88 Batch Driven: Sequences governing full CIP, SIP, and active processing phases with automatic parameter routing.

Validation Strategy: Enables independent skid validation protocols while standardizing the communication interface to the centralized supervisor.

Live Portable Skids Mimic (S88 Phase)

PLC WLAN LINK ACTIVE

Select an active operational phase below. Watch flow routes, pressures, and status matrices on the skids change instantly via the simulated wireless control stack.

PORTABLE

Pool Tank TK-01

Temp: 30.0 °C

PORTABLE

Homogenizer Skid

Pres: 15,000 psi

Speed: 100 RPM

PORTABLE

Pool Tank TK-02

Temp: 30.0 °C

Simulate Batch Phase:

PHASE LOG: Standard automated production phase active.

S-88 Batch

S88 Recipe Database Configuration

Select a formulation recipe below to simulate PLC download sequences.

RECIPE ID	TARGET PRESSURE	HOMOG SPEED	PASS CYCLES
M-100 (Sterile Vaccine)	15,000 psi	100 RPM	3 Passes
M-101 (Enzyme Blend)	12,000 psi	120 RPM	2 Passes
M-102 (Antibiotic Master)	18,000 psi	150 RPM	4 Passes

PLC Registry Stack

Loaded Batch Execution Context

Active Recipe: M-100

Target Pres: 15,000 psi

Speed Target: 100 RPM

Pass Targets: 3 Passes

Manual Maintenance Solenoid Override

Critical Utilities SCADA / Pharmaforce (USA)

Utilities Process Control System

PLC: ControlLogix L-71 SCADA: FactoryTalk View SE Net: ControlNet Fiber

Utility System Scope

Pions engineered the comprehensive Utilities System Control software to monitor, control, and seamlessly distribute critical utility media required for aseptic pharmaceutical manufacturing across multiple stages:

Formulation

Aseptic Filling

Lyophilization

Software & Control Architecture Specs

PLC Level Software

Studio 5000 Logix Designer

Handles deterministic loop control, PID valve mixing, and sanitization recipes directly on the ControlLogix L-71 CPU.

SCADA Server v12.0

FactoryTalk View SE Server

Centralized database managing live tag mapping, distributed alarms, historic archives, and 21 CFR Part 11 electronic records.

HMI Clients

FactoryTalk View SE Clients

Operator station terminal environments visualizing direct mimics, manual parameter overrides, and real-time trends.

Live Utilities SCADA Console

Replicating central FactoryTalk View client terminal pages with real-time PLC telemetry sync.

PharmaForce US NETWORK: ControlNet Fiber OK

SCREEN ID: CHILLED WATER LOOP - P&ID MIMIC

USER: admin_pions

TIME: 10/18/2012 10:59:35 AM

GENERATION STAGE

Chiller CH-1 RUNNING

Coolant Temp: 3.1 °C

Chiller CH-2 RUNNING

Coolant Temp: 3.3 °C

Chiller CH-3 STANDBY

Coolant Temp: --.- °C

LOOP PUMPS

PUMP M-M924_K1

K1 Core Primary 55.7 %

PUMP M-M924_L1

L1 Standby Boost 55.7 %

PUMP M-M924_M1

M1 Auxiliary Loop 0.0 %

FLOW VALVES

TCV-M924-7 (Air Mix)

0.0 % (CLOSED)

TCV-M924-12 (ByPass)

0.0 % (CLOSED)

PIT-M924-17: 50.1 psi

TIT-M924-18: 3.8 °C

CONSUMER LOOPS

Formulation Jackets Suite 1 & Suite 2

CW Flow Rate: 14.2 m³/h

Aseptic Filling Line Tunnel Cooling

CW Flow Rate: 8.5 m³/h

Lyophilization Loop Primary Sub-Cooling

CW Flow Rate: 18.0 m³/h

Simulated Loop Load:

*Overriding Chillers or adjusting load updates loop temperature metrics instantly.

RO Water Inlet

AV-P901-04

Water Tank PW TK1 89.5 %

SANITIZATION LOOP

TEM: 16.9 °C

Delivery Pump 1 RUNNING M-P901-10

Delivery Pump 2 RUNNING M-P901-18

Adjust Hydrostatic Tank Level

Simulates real-time system feedback across analog level sensors feeding PLC tags.

PROJECTS

Deep expertise gained from the world's top life sciences companies

PLC Systems

SCADA / HMI

Network Protocols

Validation (V-Model)

Modular Recipe & Control Engineering

Verification & Validation Life Cycle

Pharmaceutical Engineering Showcases

VHP Generator HMI System

Bioreactor Vessel Automation

Critical Utilities & Isolators

Automation Platforms & Software Frameworks

Enterprise SCADA Solutions

Programmable Logic Controllers

Manufacturing Execution Systems

Enterprise Stack Architect Simulator

Vaporized Hydrogen Peroxide Generator Automation

Delivered Automation Scope

Topology & Functional System Architecture

Interactive Demonstration Panel

VHP Telemetry Points

Current Cycle Status

Adjust Phase Airflow & Injection Parameters

RTD Calibration Coefficients & Intercept Matrices

21 CFR Part 11 Electronic Event History

Automated Batch Report Generation

Operational Phase Set Parameters

Portable Formulation Equipment Integration

Portable Skid Integration & Wireless S88 Control

Live Portable Skids Mimic (S88 Phase)

Simulate Batch Phase:

S88 Recipe Database Configuration

Loaded Batch Execution Context

Utilities Process Control System

Utility System Scope

Software & Control Architecture Specs

Live Utilities SCADA Console

Adjust Hydrostatic Tank Level

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