Pharmaceutical Manufacturer Expands Greenfield Facility Compounding Capacity with a PlantPAx® Batch Solution

Introduction

Specialty pharmaceutical manufacturer partners with MAVERICK Technologies to install and implement a PlantPAx batch solution as part of a Greenfield startup to expand pharmaceutical production.

Objective

A pharmaceutical manufacturer engaged MAVERICK to be their trusted partner in the field construction and installation of Rockwell Automation’s PlantPAx batch solution at a greenfield site. The customer required MAVERICK to complete the project while the facility was still being built, trusting the MAVERICK team to navigate the challenges associated with this request.

Results

Initially, MAVERICK was engaged in a fixed-price project, but the team’s role was quickly expanded to work alongside the customer’s main contractor in charge of field construction, ensuring requirements were met. During the greenfield project, significant customer stakeholder turnover became an issue, so the customer relied on MAVERICK, viewing the team as the onsite Main Automation Contractor (MAC) leader. MAVERICK presented the customer with various software solutions for efficient operation and then helped with the acquisition and setup of a new batch solution software. The team also corrected technical errors within the customer’s third-party system designs and drawings while onsite, ensuring efficient operation. The project was completed successfully, with the pharmaceutical manufacturer interested in consulting MAVERICK again for a potential Phase II project.

Solution

The MAVERICK Team:

• Discussed project scope and in-house standards with the customer, while determining the overall schedule for the customer’s PlantPAx solution implementation.
• Completed and finalized the design and hardware recommendations for the project’s network infrastructure, after customer review and confirmation.
• Commissioned panels based on the overall system and panel design from an additional firm.
  ● Helped the customer fix existing system design and drawing errors.

• Completed official SAT to validate overall batch solution functionality and transferred all project records, field construction specs and operational advice to customer operations team, closing out the solution migration project.
• Created graphics for human-machine interface (HMI) displays and iterated based on customer feedback.
• Installed and implemented all hardware and batch software to finalize system startup and conducted an initial water run and engineering batch validation, making minor adjustments as necessary.
Overall, MAVERICK was able to work with the customer and additional stakeholders to support Installation Qualification Operation Qualification (IQOQ), batch solution system startup, water run testing and engineering batch validation. The MAVERICK project team was committed to the customer’s schedule, working through weekends and holidays to alleviate delay impacts. With the PlantPAx batch solution successfully implemented, the greenfield compounding facility could begin operation, expanding the pharmaceutical company’s production.

The MAVERICK Difference

MAVERICK overcame several greenfield site challenges and elevated their responsibilities over the course of the project to successfully deliver a PlantPAx batch solution, illustrating the robustness and reliability of the project team. When major turnover and project delays threaten to derail a project, look for MAVERICK Technologies to step up and lead by example to drive the top-tier results you require.