IIoT for Pharma | Boost Efficiency & Product Quality

Key Challenges in the Pharmaceutical Sector

Complex Regulatory Compliance

Ensuring stringent regulatory requirements is critical in pharmaceutical manufacturing. Without real-time monitoring and comprehensive data analysis, streamlining compliance processes becomes a major issue.

Optimizing Product Quality

For pharma companies, maintaining consistent product quality across complex manufacturing processes is a continuous challenge. Lack of visibility into production parameters and quality metrics leads to deviations and substandard product quality.

Enhancing Operational Efficiency

Efficient resource management and minimizing downtime in pharmaceutical manufacturing are essential for operational efficiency. Without analytics, it can be challenging for you to optimize manufacturing processes, reduce cycle times, and maximize equipment effectiveness.

Managing Complex Supply Chains

Pharmaceutical supply chains involve diverse raw materials and intricate logistics. Without precise management of batch genealogy, getting the complete data for impacted batches can get strenuous and complicated.

Ensuring Efficient and Safe
Pharmaceutical Production

From API production to packaging, Facttwin enables pharmaceutical manufacturers
to optimize processes, ensure quality, and drive efficiency through real-time insights.

Predictive Insights and Optimization

Anticipate maintenance needs by utilizing Facttwin's predictive analytics coupled with machine learning algorithms. Optimize the output of your production lines by proactively addressing the key issues.

Adhere to Regulations

Facttwin helps you ensure compliance with stringent regulations by offering unmatched batch traceability, reporting, and data management. From raw material receipt to final product release, ensuring the consistent delivery of high-quality, safe, and effective medicines to patients worldwide.

Improve Quality and Output

Count on our real-time monitoring of quality KPIs to eliminate vulnerabilities in the pharmaceutical production lines. Monitor your equipment more efficiently by choosing preventive and condition-based practices over schedule-based maintenance practices.

Real-Time Process Monitoring

Facttwin enables pharmaceutical companies to monitor critical manufacturing processes in real time with its advanced data acquisition and deep analytics. By leveraging the data, you can identify deviations, optimize process parameters, and ensure high operational performance.

Overcoming Pharmaceutical Manufacturing
Challenges with IIoT Solutions

With Facttwin’s seamless data acquisition and predictive analytics,
pharmaceutical manufacturers can optimize processes and ensure compliance effortlessly.

Driving the Smart Pharmaceutical Factory Transformation

Get the much-needed edge in the pharmaceutical sector by choosing Facttwin Connect and Facttwin Intelligence products and turn your operations into smart factories.

Automated alerts and notifications for proactive issue identification and resolution
Real-time data acquisition from various pharmaceutical equipment and sensors.
Access a unified IIoT platform for seamless data integration from multiple sources.
Optimize production and minimize downtime with predictive insights
Receive automated alerts for proactive issue identification and resolution.

Real-Time Monitoring of API Production Processes

Facttwin helps simplify the complex processes involved in Active Pharmaceutical Ingredient (API) production, including chemical synthesis, fermentation, extraction, and purification, by acquiring real-time data from various equipment used in API production.

Monitor key parameters like temperature, pressure, pH, and dissolved oxygen to optimize API quality.
Oversee the performance of centrifuges, filters, and chromatography columns for API purification.
Track API drying efficiency and particle size reduction to ensure consistent powder properties.

Optimizing Formulation and Tableting Processes

Post API production, various excipients are mixed with the same to create the final drug formulation, making it one of the most crucial steps to monitor. This is where Facttwin provides you with complete visibility.

Monitor blenders and mixers for homogeneous API and excipient distribution.
Track wet or dry granulation efficiency to optimize particle size and tablet compressibility.
Optimize tablet press performance, including compression force and hardness, for consistent quality.
Acquire data from coating equipment to ensure thickness, uniformity, and efficiency.

Ensuring Quality and Adhering to Compliance

With Facttwin Intelligence, you can track both quality and compliance KPIs of your pharmaceutical manufacturing process in real-time.

Monitor acceptable product percentages in each batch to identify improvement opportunities
Track defective units produced to identify root causes of quality issues.
Drive continuous improvement by tracking deviations from standard operating procedures.
Ensure traceability by using batch genealogy to link raw materials, intermediates, and final products.

Begin your journey towards
operational excellence with Facttwin

Take the first step towards data-driven excellence

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Frequently Asked Questions

How does Facttwin ensure data security and integrity in a regulated environment like pharmaceuticals?

Facttwin understands the stringent security and compliance requirements of the pharmaceutical industry. We prioritize data protection and integrity with:

Role-based access controls to restrict data visibility based on authorization levels.
Encryption of data both at rest and in transit.
Immutable audit trails for comprehensive tracking of data changes.
Adherence to industry standards (e.g., GAMP5, 21 CFR Part 11) and support for validation processes.

Can Facttwin's Smart Factory solution monitor cleanroom environments and critical environmental parameters?

Yes! Facttwin’s Smart Factory solution offers real-time monitoring of critical environmental parameters essential for pharmaceutical manufacturing, including:

Temperature
Humidity
Differential pressure
Airflow
Particle counts

Our system triggers alerts upon deviations from specified thresholds, safeguarding product quality and ensuring compliance.

How does Facttwin's Machine Health Monitoring solution detect early signs of equipment wear or potential failures?

Facttwin’s Machine Health Monitoring solution utilizes advanced analytics and machine learning algorithms with real-time sensor data, concentrating on:

Vibration analysis: Detecting subtle changes indicative of misalignment, bearing wear, etc.
Temperature monitoring: Identifying abnormal heat patterns suggesting impending breakdowns.
Pattern recognition: Learning normal operating baselines to identify anomalies.

Our predictive model alerts you on potential issues well in advance, allowing for proactive maintenance.

Does Facttwin provide tools for statistical process control (SPC) and how does this help with quality assurance?

Facttwin offers integrated SPC tools that enable pharmaceutical manufacturers to:

Monitor critical process parameters in real-time.
Establish control limits and identify out-of-control situations.
Visualize process trends and patterns to uncover potential quality issues.

This proactive SPC approach enhances product consistency and reduces the risk of costly deviations.

Can Facttwin generate customized reports for regulatory audits?

Facttwin streamlines audit preparation by providing:

Automatic generation of tamper-proof data logs for equipment performance, environmental conditions, and maintenance activities.
Customizable reports aligned with specific regulatory requirements.
Easy search and retrieval of historical data.

Our comprehensive reporting capabilities simplify compliance and reduce audit-related stress.

Still have questions?

Get in touch with us to know more

Driving Optimum Performance in Pharma Manufacturing with Real-Time Insights