Smarter Pharmaceutical Processing with PlantPAx & FactoryTalk Batch

Cybertrol partnered with a leading biotech manufacturer to modernize and expand their Research and Development Center in Wisconsin, implementing advanced process control and batch automation systems that enabled continuous production during renovation and positioned the facility for expanded manufacturing capabilities.

A leading biotech manufacturing company began a major renovation and expansion of its Research and Development Center (RDC) facility in Wisconsin. Originally used for research and development, the RDC was transitioning into a full-scale manufacturing center following the relocation of its R&D groups. With production already underway and plans to bring in new fermentation and purification systems, the facility needed a modernized process control system to support the increased scope of operations—without disrupting ongoing production.

Cybertrol Engineering was selected to provide a full control and information system integration solution that would meet these challenges head-on, implementing Rockwell Automation’s PlantPAx® DCS platform along with FactoryTalk® Batch to support complex bioprocessing workflows.

Project Goals 

• Replace the outdated process control system to support expansion into five plant areas.
• Introduce a highly automated batch process platform to standardize production and reporting.
• Maintain uptime for the existing fermentation suite throughout the renovation.
• Deliver a fully integrated solution across control panels, industrial networking, data systems, and batch software.

Cybertrol’s Role and Approach

Cybertrol Engineering provided a comprehensive package of services—from design and panel fabrication to programming, training, and commissioning—ensuring a successful upgrade of the RDC facility with minimal production disruption.

Key components of Cybertrol’s scope included:

• Designed and implemented a facility-wide industrial network and new Industrial Data Center.
• Upgraded hardware across five plant areas, including new controller panels with GuardLogix L81ES safety PLCs, Flex 5000 remote I/O panels, and PowerFlex® 755 VFD panels.
• Installed ThinManager for streamlined HMI management, using OnLogic thin clients and industrial widescreen monitors.

Batch Process Implementation

• Engineered the system using Rockwell Automation’s PlantPAx and FactoryTalk Batch to bring batch automation in line with ISA-88 standards.
• Developed recipes and control sequences for fermenters, CIP skids, and related utilities.
• Enabled centralized batch scheduling, production sequencing, and material consumption tracking with FactoryTalk Batch View.

Data and Reporting Systems

• Integrated SCADA and historian systems using FactoryTalk View SE Distributed and FactoryTalk Historian.
• Built real-time and historical reporting via SQL Server Reporting Services (SSRS) and out-of-the-box FactoryTalk Batch reports, including:
  • Fermenter Batch Reports
  • CIP Reports
  • Waste Neutralization Chemical Usage Reports

Validation and Documentation

• Delivered comprehensive design documentation, FAT/SAT protocols, and IQ/OQ support for validation.
• Provided detailed software documentation and CAD drawings for all panel assemblies.
• Ensured backup and recovery measures were in place across PLC, HMI, and server systems.

Managing Downtime and Onsite Execution

A central challenge of the project was maintaining production continuity within the existing Fermentation A suite while construction and installation occurred around it. Cybertrol coordinated closely with the biotech manufacturer’s project teams to phase installation and execute switchover activities with precision timing. Field engineers provided I/O checkout, commissioning, and testing support onsite as equipment areas came online.

Delivered Results 

• Fully Integrated Process Control System: The new PlantPAx DCS platform, combined with FactoryTalk Batch, enabled precise process control across expanded manufacturing suites with improved visibility and consistency.
• Improved Operational Efficiency: Batch automation helped standardize production procedures and reduce manual interventions.
• Data-Driven Decision-Making: Real-time and historical reporting tools provided operations staff with actionable insights into equipment usage, cleaning cycles, and chemical consumption.
• Minimal Disruption to Production: Careful planning and execution allowed the Fermentation group to continue manufacturing without unplanned downtime.

Why Cybertrol 

Cybertrol was selected for their proven expertise in integrating complex control and IT systems in GMP-regulated environments. With a deep understanding of both industrial automation and the biotech production landscape, Cybertrol delivered a solution that aligned with industry standards while meeting the customer’s specific needs for reliability, scalability, and compliance. 

Technologies Used 

• Control Platform: Rockwell Automation PlantPAx®
• Batch Management: FactoryTalk® Batch
• HMI and SCADA: FactoryTalk® View SE Distributed
• Data and Reporting: FactoryTalk® Historian, SQL Server, SSRS 
• IT Infrastructure: ThinManager, Industrial Data Center, Stratix® switches, DMZ firewall
• Drives and I/O: PowerFlex® 755 VFDs, Flex 5000™ I/O

Conclusion

Cybertrol’s turnkey integration of modern control and information systems helped this biotech manufacturer transform its RDC facility into a state-of-the-art manufacturing site. Through strategic planning, precise execution, and leading-edge automation technology, the company is now well-equipped to scale production and support new product lines—confident in the reliability, traceability, and efficiency of its upgraded process control system.