Systems and Solutions for the Process Industry

processnews

12th edition July 2|2007

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Partial Stroke Test:

ExtendingMaintenanceIntervalsBraumat PCS 7 andSitrans P at Ziemann:

Pilot Micro-brewery

Partial Stroke Test:

ExtendingMaintenanceIntervalsBraumat PCS 7 andSitrans P at Ziemann:

Pilot Micro-brewery

Faster, Fitter PharmaSystems and solutions for the pharmaceutical industry

Faster, Fitter PharmaSystems and solutions for the pharmaceutical industry

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The new production facility for influenzavaccine at GSK Biologicals in Dresden wasautomated using Siemens componentsand concepts

In just three weeks, Siemens installeda new process control system based on Simatic PCS 7 at JanssenPharmaceutica in Belgium

Simocode pro enables high plantavailability in the water treat-ment unit at a sugar refinery ofSüdzucker in Germany

process news 2/2007

Cover picture:Liquids & Creams Facility, Janssen Pharmaceutica

Photo: Wolfgang Geyer

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3 EDITORIAL

4 NEWSContinuous monitoring of blood supplieswith RFID

USP purified water system upgrade for Puerto Rico plant

Simatic PCS 7 and switching system for printing plate production in China

New EU directive simplifies certification of process instruments

COVERPharmaceutical industry

6 Doubling CapacityExpansion of the GSK Biologicals site in Dresden

Pharmaceutical industry10 Answering the Need for Innovation

Interview with Marc Sohet, head of globaltechnical services at GSK Biologicals

Pharmaceutical Industry12 Added Value

Migration of the process control system to Simatic PCS 7 at Janssen Pharmaceutica

Pharmaceutical Industry14 Fitter, Faster Pharma

Innovation and expertise for the pharmaceutical industry

Pharmaceutical Industry15 Accelerating Pharmaceutical Innovation

Sipat PAT software for pharmaceutical applications

CASE STUDIESSugar Industry

22 Reliable at Full LoadMotor management with Simocode ensures system availability at Südzucker

Breweries26 Pilot Microbrewery

Braumat PCS 7 and Sitrans P in brewery pilot plant

Sensors28 An Eye for Detail

Vision sensors optimize company logistics at Zentis

Process Instrumentation30 Safe Control

Univar enhances operations with new level system

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As partners to the pharmaceutical industry, we areliving in exciting times. New regulations, new tech-nologies, new products – all provide our customerswith many new opportunities. However, there are also new challenges. Increasing R&D costs as well asgreater competition in a globalized market requirecourage – the courage to rethink and take innovativeapproaches in development, production, and distri-bution. Reason enough to make our work in thepharmaceutical industry the focus of this issue ofProcess News.

We are proud to accompany our customers on thischallenging journey into the future, supporting themwith our expertise, experience, and technology. Forthis reason, we have expanded our product portfolioand consistently pushed ahead with the introductionof new technologies. And we are successful togetherwith our customers. In Dresden we implemented acomprehensive solution for GSK Biologicals for themanufacture of flu vaccines, and in Belgium we mod-ernized the process control technology within a shorttime using our Simatic PCS 7 process control system.These examples will be showcased in this issue, alongwith many other innovations and applications.

The growing importance of the pharmaceuticalindustry and also our commitment to it was docu-mented by impressive illuminated advertising in con-junction with our appearance at the most importantpharmaceutical event in the United States – Interphexin New York from April 24 to 26, 2007 – in the heart of New York City, in Times Square. For me as head ofthe Pharma Competence Center, this was a reason tolook back with pride and satisfaction on our perfor-mance. And, simultaneously, an incentive to use ourinnovative and proven technologies in the future tofurther help our customers achieve their goals.

I hope this issue of Process News can give you somevaluable ideas!

Simatic VS130-2 vision sensors read datamatrix codes on outer packaging at Zentisin Germany at high speeds and withreliable results

process news 2/2007

Wolfgang ScheidingHead of the Competence Center PharmaSiemens Automation and Drives

Dear Readers:

EDITORIAL

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TECHNOLOGIESProcess Automation

17 Simple, Modular, and FlexibleSimatic PCS 7 Lab: Automation system for experiments in process laboratories

Process Safety18 Extending Maintenance Intervals

The Partial Stroke Test as a module in the process safety concept

Advanced Process Control21 Focus on Control

Advanced Process Control solutions increase process controllability

Process Instrumentation24 Innovative, Robust, and Versatile

New products for process instrumentation

31 DIALOGUE

process news 2/2007

4 NEWS

A leading pharmaceutical company has chosenSiemens Water Technologies to supply a

turnkey USP (United States Pharmacopoeia) puri-fied water system upgrade for its biotechnologylaboratory in Puerto Rico. The US $1.1 millionproject will begin operation in April 2007.

The company is adding an additional system tothe two systems already supplied by Siemens in2003. Each automated train includes pretreatmentequipment and a reverse osmosis (RO) systemfollowed by a continuous deionization system.

The use of these hot-water-sanitizable tech-nologies allows the pharmaceutical plant to takewell water and reduce the conductivity, total or-ganic carbon, and bacteria levels to those requiredto validate the water as USP purified water. �

S iemens has collaborated with severalpartners to develop a solution for the

comprehensive monitoring of blood do-nations that is based on radio-frequencyidentification (RFID). In addition to makingtransfusions safer in the future by identify-ing blood via radio chips – virtually elimi-nating the possibility of mix-ups – the sys-tem is also equipped with a temperaturesensor that enables continuous monitoringof the cooling chain.

The new system’s RFID chips with tem-perature sensors are affixed to blood bags,and the blood temperature can be called up at any time using radio-equipped read-ing devices. The chips must be able towithstand extreme conditions. They mustundergo a sterilization and pasteurizationprocess during production, for instance, and are later subjected to a force of up to 5,000 g when being processed in a cen-trifuge. The Siemens RFID chips passed allthe required tests, and after the project iscompleted the appropriate authorities willevaluate them to determine their suitabili-ty for commercial use. The new system isscheduled to be ready for use in 2008.

Specialists at Siemens Automation andDrives in Nuremberg and Vienna, as well as

Continuous monitoring of bloodsupplies with RFID

Safe Transfusions

Identificationvia RFID chipsvirtuallyeliminates thepossibility ofblood supplymix-ups

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experts from Siemens IT Solutions andServices in Vienna, have been working onRFID labeling of blood bags for years.Siemens developed its new RFID temper-ature-sensor system in cooperation with

Schweizer Electronic, the blood bank ofGraz University Hospital, and the blood bagproducer MacoPharma. �

Find out more:www.siemens.com/water

Find out more:www.siemens.com/rfid

USP purified water system upgrade for Puerto Rico plant

Doubling Total Flow

process news 2/2007

Anew EU directive (MID Directive), whichcame into effect at the end of October

2006, aims at simplifying the free trade ofprocess instrumentation devices in Europe.It internationalizes and eases the approvalsprocedures by reducing the number of ap-provals required. Each process instrumen-tation device requires only one certificationto allow it to be used Europe-wide.

Internationally oriented customers inparticular will benefit from this directive ina number of ways. They can now use thesame process instrumentation device typein several countries. They also have moreprocurement alternatives and thereforemore options when attempting to select thebest and most cost-efficient device fromthose available.

Although the MID Directive is relativelynew, some companies have already speci-fied devices that will obtain approvals in ac-cordance with the directive. Siemens is oneof these companies, having already select-ed three of its flowmeters – Sitrans F M MAG8000 CT, Sitrans F M MAG 6000 CT, andSitrans FUS380. �

Kodak’s Graphic CommunicationsGroup (GCG) is one of the three mar-

ket leaders for offset printing plates; itsstrengths lie especially in the manufac-ture of modern “computer to plate” (CTP)printing plates. Kodak’s customers areprimarily large printers and publishingcompanies.

Kodak’s GCG contracted Siemens tosupply the PCS 7 process control systemand low-voltage switchgear for its Coat-ing Preparation Facility (CPF) – a subunitof the new facility for manufacturing off-set printing plates. In the manufacture ofoffset printing plates, an aluminum stripis first (electro)chemically treated and

then has a light- or heat-sensitive coat-ing applied in the CPF. The image is latertransferred onto this coating when im-aging the printing plate.

Kodak’s first printing plate line in Chi-na, owned by the Kodak China GraphicCommunications Company Ltd., is beingbuilt at an existing Kodak site in Haicang,a new special industrial estate in the cityof Xiamen in Fujian Province. What isunique about this project is that Siemensproducts are now being used for the firsttime on a large scale at this location thatis dominated by Siemens competitors.The Siemens engineering team fromFrankfurt am Main was already involved

in the initial basic engineering in 2004and has been entrusted with the detailengineering, the procurement of impor-tant subsystems, and the project man-agement for the integration of the sub-systems since August 2005. Assemblybegan at the end of 2006, and the sys-tem should begin operation in the sec-ond half of 2007. Siemens in Karlsruheis now also involved as a hardware andsolution provider. �

Simatic PCS 7 and switching system for printing plate production in China

Computer to Plate

Find out more:www.siemens.com/sp

New EU directive simplifies certification of process instruments

Open Market

At the Siemens test laboratory, the devices were prepared for theapprovals procedure according to the EU directive

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Find out more:www.siemens.com/processinstrumentation

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process news 2/2007

6Pharmaceutical Industry

COVER

Expansion of the GSK Biologicals site in Dresden

DoublingCapacityThe GSK Biologicals facility in Dresden is one of thecompany’s key plants for flu vaccine production. WhenGSK Biologicals decided in 2005 to double the productioncapacity in Dresden to 60 million doses per year, theproject had to be completed in record time to meet the deadline for the 2008/2009 flu season. Experiencedpartners and a solution based on proven systems andproducts from Siemens helped GSK Biologicals completethe modernization on schedule.

The new influenzavaccine productionfacility in Dresden willdouble the productioncapacity in Dresden to 60 million doses per year

process news 2/2007

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says Denis Fabris, senior project manager

in Dresden. “So we are talking about a com-

pletely new pharmaceutical production line

in addition to the existing plant.” The main

aim was, of course, to increase the bulk

manufacturing capacity and to increase the

capacity for filling syringes. However, this

project also offered an opportunity for GSK

to improve both the process and the pro-

duction practices.

A major challenge during the expansion

was the tight schedule. In order to be able

to produce the first commercial batch in

time for the flu season of 2008 and 2009,

the plants had to be built in about 20 per-

cent less time than is usually required for

such a project. Denis Fabris explains: “The

F lu vaccines are produced in a com-

plex, multistage process. Traditional-

ly, influenza vaccines are produced

in fertilized chicken eggs. Eleven days

after fertilization, the influenza virus – each

strain is grown separately – is injected into

the eggs and accumulates in the fluid sur-

rounding the embryo. A high-yielding

donor strain is co-injected. The embryo be-

comes infected so that the virus can multi-

ply. After several days of incubation, ma-

chines open the eggs and harvest the virus.

Then the virus is carefully purified, chem-

ically inactivated, and used to produce the

vaccine.

Dresden is GSK Biologicals’ center of ex-

pertise for flu vaccine production, offering

the required know-how and technology, so

when the company decided to increase its

capacities for flu vaccine, expanding the

facility in Dresden was the logical choice.

Challenges and opportunities

The expansion work in Dresden comprised

building a totally new production line for

everything from egg inoculation to inacti-

vation, including inoculation and harvest-

ing units, incubators, ultracentrifuges, and

units for ultrafiltration and storage vessels.

“We also increased the boiler capacity for

industrial steam, and we have our own elec-

trical substation, air compressor, water

production, black and clean utilities, a lab-

oratory, a warehouse, and related offices,”

process news 2/2007

8Pharmaceutical Industry

COVER

Parts of the automation solution in Dresden use the component-based automation approach, a comprehensiveconcept for drug manufacturing that reflects the followingrequirements of the pharmaceutical industry and the OEMs:

B Scalability and modularity B Suitability for different equipment typesB Horizontal integration of linesB Vertical integration (e.g., for reporting or OEE) B Open industry standards B Compliance with GMP regulations

Each OEM can equip its machine with either a Simatic or aSimotion controller, scalable for the individual functions thatit needs to perform. Local operation and visualization of amachine are realized using the SCADA software WinCCflexible. Each machine can be separately developed and GMPqualified on its own.

Using Profinet and component-based automation, allmachines are horizontally integrated very rapidly and effi-ciently and linked to a central WinCC SCADA system for linesupervision, batch management, and equipment statusoverview.

The use of open communication standards also allows theintegration of third-party components. Vertical integrationwith the plant’s enterprise resource planning (ERP) system isperformed by a manufacturing execution system (MES) thatlinks the data collected from the production lines withenvironmental control data.

The ERP, MES and central SCADA systems together deliverall the needed functionalities for improved manufacturingperformance, built-in quality, and an optimized supply chainin the drug manufacturing plant.

The package units exploit thecomponent-based automationconcept from SiemensG

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Component-based automation in pharmaceutical production

prerequisites for all our projects are quali-

ty and safety. For me as a project manager,

the challenge was to build a new plant

meeting these stringent requirements in

a very short time. Consequently, we devel-

oped a strategy to shorten the project

phase, with one focus on shortening pro-

curement activities by using a standard

solution from Siemens.”

Proven solutions and experiencedpartners

The construction began in August 2005

with more than 250 construction workers

on the site in two-shift operation during

the peak construction time. The structural

work was completed in June 2006, and GSK

Biologicals is currently in the operation

qualification phase. After that, the facility

will undergo performance qualification

with eggs and produce a consistent lot

to demonstrate that production quality is

strictly stable. Production of the first com-

mercial lot is scheduled for March 2008,

so that the vaccine can be delivered to doc-

tors and patients in September 2008 when

vaccinations begin for the upcoming flu

season.

Siemens was involved in this project at

several levels. Siemens was directly con-

tracted to implement a uniform building

management system for all production-

related air-conditioning units and utilities,

including project management, software

engineering, and hardware supply. This

system is based on Desigo PX. Siemens was

also contracted to automate the air-condi-

process news 2/2007

9

Process instrumentation for pharmaceutical production

For another project at GSK Biologicals, Siemens was awarded thecontract to automate key parts of a vaccine plant, including the air-conditioning and various supply units (utilities), and also to deliverthe process instrumentation for the utilities.

Measuring tasks for the project included controlling and moni-toring levels, temperatures, pressures, and flow rates as well as pHand conductivity values in tanks and vessels. Measuring mediainclude fluids such as glycol water, cooling water, deionized water,industrial water, city water, and others.

From the wide range of Siemens process field instruments,numerous different device types can be used to perform thesemeasuring tasks, for example, the Sitrans LC 500, which is de-

signed for operation under extreme and critical process condi-tions.

Siemens offers a comprehensive line of process instrumenta-tion products for pharmaceutical applications:B Pressure: Sitrans PB Temperature: Sitrans T KB Flow: Sitrans F O flowmeterB Level: Sitrans CLS 200 inverse frequency shift capacitance

switch and Sitrans LC 500 inverse frequency shift capacitancelevel controller

B pH: Sipan pH liquid analyzerB Conductivity: Sipan Cond liquid analyzer

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tioning system for the incubators, which

are one of the most critical components of

vaccine production. The chicken eggs that

are being incubated require strictly con-

trolled ambient conditions.

Another important part of the Siemens

contribution was implementation of the

automation concept for the package units

in the vaccine production line. The concept

uses the component-based automation

approach based on Profinet and Simatic

technology, in which package units are de-

signed as completely validated units that

need only be connected to the plantwide

Profinet network via a specified interface.

This approach helps facilitate the integra-

tion of package units supplied by different

vendors and significantly reduces the work

required for validation (see box).

With GSK Biologicals, Siemens defined

the system standards and performed a

proof of concept on a prototype. After that,

Siemens specified design guidelines for all

OEMs involved in the project for the types

of hardware and system software to be ap-

plied in the automation of package units.

These guidelines also specified the data

flows between the package units and the

production data management system and

the interface to the environmental and

alarm monitoring systems as well as be-

tween the package units via Profinet.

Siemens supported both OEMs and the sys-

tem integrator in implementing the auto-

“The challenge was to build a new

plant meetingthese stringent

requirements in avery short time.”

Denis Fabris, GSK Biologicals senior project

manager in Dresden

�

process news 2/2007

10Pharmaceutical Industry

COVER

need a certain amount of time to develop a

product, to build a facility – and all the

while the product itself is still going

through the clinical trials. Obviously this

can cause problems, because even if you

have a new product, you still need a lot of

time before you can go to market. This costs

a lot of money, and you need a strong com-

pany to sustain such a process. A vaccine is

a biological product, and as such it is very

difficult to characterize. So to produce a

vaccine, the process has to be robust in or-

der to ensure the quality of the product.

This is also important for inspections: we

have to prove to the inspectors that we are

in full control and have full knowledge of

our process. We have to know what is be-

hind, for example, a signal lamp. We need

full system transparency to prove that our

process is robust.

Because a vaccine is an injectable prod-

uct, the conditions have to be as perfect as

possible, and any contamination has to be

avoided. In vaccine production, the staff is

a main source of possible contamination, so

you need a high level of containment be-

tween the personnel and the process – and,

of course, you need space. So what we need

is innovation – to reduce costs, but mainly

to reduce contamination.

Interview with Marc Sohet, head of global technical services at GSK Biologicals

Answering the Need for InnovationSeizing market opportunities in the vaccine business requires a strong company, not only to finance research anddevelopment but also to support time- and capital-intensive investments in new facilities. Moreover, vaccineproduction requires robust, fully controllable processes. According to Marc Sohet, his company views innovationas the key to solving these challenges – together with innovative and reliable partners.

Mr. Sohet, the vaccine market is currently

growing strongly, with a projected growth

of more than 10 percent per year until

2012. How do you intend to seize these

opportunities?

Marc Sohet: In order to grow in our busi-

ness, you have to plan five years ahead. You

Publ

icis

“In order to grow in our business,you have to planfive years ahead.”

Marc Sohet, head of global technical services at GSK Biologicals

mation solution. The system integrator

on/off engineering was responsible for the

integration of the package units. “We are al-

so very satisfied with this aspect of the proj-

ect implementation,” says Denis Fabris.

The plant is equipped with Siemens sys-

tems throughout. More than 50 Simatic S7

PLCs are installed in the various systems at

the Dresden facility, and Simatic WinCC and

Simatic WinCC flexible are used as visuali-

zation systems. Siemens also supported

GSK Biologicals with a broad range of ser-

vices – for example, installation, commis-

sioning, validation, and computer ac-

ceptance test consulting – and provided ex-

perienced personnel to support GSK

Biologicals during staff shortages.

Dedicated to success

The project is on track for the scheduled

production start-up. Thanks to the consis-

tency of the technology and solutions im-

plemented, the GSK staff is already trained

on the Siemens systems, which accelerates

commissioning. “The project is not yet fin-

ished,” says Fabris, “but so far, the collab-

oration has demonstrated a very positive

spirit. Of course, we have had some diffi-

culties and challenges, but they are being

resolved systematically.” Denis Fabris is

quite confident that the project will be

completed on time: “Siemens clearly wants

to make this project a success. When you

have this positive spirit on a project, there

is little doubt that the result will be positive

as well.” In the meantime, additional joint

projects between GSK Biologicals and

Siemens have been initiated in Belgium

and France that will also benefit from the

standardized approach implemented in

Dresden. �

Doubling Capacity

Find out more:www.siemens.com/pharmaE-mail: david.melville@siemens.com

process news 2/2007

11

What role does automation play

in this context?

Marc Sohet: Our vision for vaccine pro-

duction is a closed process in which there

is no interaction with the vaccine and its

environment – especially by personnel.

Such a process requires a high degree of au-

tomation. With regard to automation, there

are many areas of improvement where new

technologies can be introduced, for exam-

ple, Process Analytical Technology. We want

to focus on our core expertise, so we expect

our suppliers to support us in maintaining

the site – that includes technology, spare

parts, and consulting, but also training at

the site level.

Also, whenever we are building a new fa-

cility, we have to deal with the specific re-

quirements of the product and the process.

We never do the same thing twice. What we

need are contractors who understand the

complexity of the project and the complex-

ity of what we do – and who can add agility

to the process, not only in order to act

quicker, but also to understand quicker and

to present a new solution quicker. As our

facilities are quite large and very complex,

implementing a new production facility is

like trying to navigate with a very large

ship. We have many interfaces with exter-

nal parties, and due to that we have many

uncertainties and many changes.

Do you see Siemens as a partner that can

help you maneuver those large ships?

Marc Sohet: From my experience, I would

say yes. One important factor for us is the

broad range of solutions Siemens offers.

Siemens is not only a supplier of automa-

“For us, the price is not the decisiveissue – we arelooking at the totalcost of ownershipand all aspects ofthe relationship.”

tion technology, but also of building

technology and communication technol-

ogy, and is also providing the full range

of services, spare parts, and so on.

Siemens has a large research department

and is a leader in technology – also

through its shares in many leading com-

panies – and offers a good global net-

work. It is beneficial for us to work with

such a company.

Of course, the high-quality products

that have become a de facto standard so-

lution for many OEMs and other compa-

nies besides ourselves are also an impor-

tant factor in our decision to work with

Siemens. Overall, I would say that for us

the price is not the decisive issue – we are

looking at the total cost of ownership and

all aspects of the relationship.

So Siemens is a strategic partner for your

company?

Marc Sohet: Definitely. Siemens is a

partner in automation and especially in

innovation – for example, RFID (radio-

frequency identification). This is a tech-

nology that is especially important in

tracking the logistics chain of a vaccine

– to show that our product has been

correctly handled during transport, stor-

age, and so on until it has reached the

customer – as well as with respect to

counterfeiting, tampering, and modifi-

cations.

I have already mentioned Process An-

alytical Technology (an area in which

Siemens is also active), which is one pos-

sible way to improve our processes. An-

other new development in our processes

will be the disposable process in which

the active pharmaceutical product is pro-

duced in single-use process containers,

and for that we have to develop new com-

ponents, which, of course, will include

sensors and automation solutions.

Another area in which we would like to

see some improvements concerns stan-

dard interfaces between systems and

equipment so we can pick best-of-breed

solutions from various suppliers and link

them. And we want to develop new and

improved strategies for automation, be-

cause, as I mentioned before, we want to

achieve a closed process. So automation

and Siemens will continue to be of inter-

est to us in the future, too.

Thank you for speaking with us. �

�

process news 2/2007

12Pharmaceutical Industry

COVER

weeks to avoid the risk of running out of

market stock. Consequently, choosing the

right partner for this project was crucial.

Janssen wanted to keep the existing re-

mote I/O devices in place and replace only

the automation and operator systems. As

Siemens had supplied the existing process

control system, Janssen invited Siemens to

participate in the tender. After extensive

considerations, Janssen Pharmaceutica de-

cided that Simatic PCS 7 Version 6 would be

the best solution for the plant at Beerse.

Detailed study for smooth transition

Planning was everything during this

project, as Janssen Pharmaceutica senior

project manager Kris Buys confirms: “It is

essential to work out a detailed project ex-

ecution plan and project qualification strat-

egy, including documentation, and that all

work during the shutdown be planned ex-

actly in order to be able to complete the fac-

tory acceptance test.”

In the second quarter of 2004, Siemens

performed a detailed project study. The

project team defined the functional speci-

fications, software and hardware design,

and coding and internal testing. This study

also included the user requirement speci-

fications, a detailed validation plan, and a

The Beerse L&Cr liquids and creams

plant produces a wide variety of prod-

ucts for treating diverse disorders and

infections. The Beerse site comprises pilot

plants, secondary units, and research and

development facilities. The L&Cr plant pro-

duces about 50 different products and

processes 5,000 orders per year.

Batch production in the multipurpose

facility goes through several stages and is

equipped with a clean-in-place system. Wa-

ter, raw materials, and bulk ingredients are

mixed in a boiling vessel and a processing

unit. Then they are transferred to holding

and buffering tanks before the semi-

finished product is transferred to the sec-

ondary unit for finishing and packaging.

A new core

The existing process control, based on

Simatic S5 controllers and the Coros LS-B

supervisory system, had not undergone a

major upgrade in 12 years, and some sys-

tem components were approaching the end

of their service life. Consequently, in 2003,

Janssen Pharmaceutica decided to mod-

ernize the system and replace the automa-

tion level with a new solution. The compa-

ny also wanted the new system to provide

possibilities for future expansions and up-

grades, as the frequency of control system

upgrades is expected to rise. Additionally,

the new system was to be capable of linking

with the higher-level manufacturing exe-

cution system (MES) and enterprise re-

source planning (ERP) system.

The major challenge for the system mi-

gration, however, was the very tight time

frame for the conversion. The production

shutdown period was not to exceed three

Migration of the process control system to Simatic PCS7 at Janssen Pharmaceutica

Added ValueIn just three weeks, Siemens installed and commissioned a new processcontrol system at the liquids and creams plant of Janssen Pharmaceuticain Beerse, Belgium. Detailed preparation and an experienced projectteam were the decisive factors in completing this challenging project –and the entire validation and qualification of the new system – in thistight time frame.

Project highlightsB Migration of process control

system for multipurpose batch

production facility

B Tight time frame of only three

weeks for the migration

process news 2/2007

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risk and 21 CFR Part 11 assessment. Siemens

was also responsible for the detail engineer-

ing, including GxP and business-criticality

analysis, evaluation of various solutions and

migration approaches, and updating and

finalizing the user requirement specifi-

cations and the final tender document.

In mid-2005, the execution phase of the

new solution implementation was initiated.

Siemens took on the engineering of the

new system hardware, including installing

and commissioning the system on-site in

Beerse, and was also responsible for the op-

erator training. Siemens also provided val-

idation support and compiled the docu-

mentation for qualification and validation.

To mitigate the risks associated with the

migration, Siemens performed a pretest of

the new system during the Christmas

break. The new PCS 7 system was connect-

ed to and tested with all types of I/O devices

to make sure there would be no problems

during the real shutdown.

Experienced partners

All systems were up and running before

the final project deadline of August 1, 2006.

This success was made possible by the ex-

cellent preparation and good team effort,

as Kris Buys recalls: “The shutdown period

was very intense. During one weekend, the

team took the old system out and put all the

new systems in, so we had an operational

system for the testing and qualification pro-

cedures after just one weekend. And the re-

sult was very positive: after the system went

into operation, we did not have even a sin-

gle major incident. This was, of course, due

to the excellent combined preparation of

Janssen and Siemens.”

The project team from Siemens also in-

cluded individuals who had already imple-

mented the old Simatic S5 / Coros LS-B sys-

tem and who were familiar with both the

plant and the control system. “For us, this

was a major added value,” says Buys. He

was also quite impressed with the quali-

fication and validation support: “Siemens

provided us with a very good qualification

file that was very defensible with the FDA –

which, of course, is very important.” �

In the liquids and creams plant, about50 different products and 5,000 ordersper year are processed in multistagebatch processes

Local operation is enabledby Simatic Panel PCs

Find out more:www.siemens.com/pharmaE-mail: bart.moors@siemens.com

clauspeter@siemens.com

New system architecture B Production

B 1 batch Server + batch API for CIP scheduling

B 1 redundant PCS 7 server with 250,000 variables (in use: +/- 170,000)

B 1 engineering station (unlimited license)

B 1 redundant domain server B Simatic Logon/Electronic Signature

B 19 PCS 7 clients B 8 OS clientsB 11 Panel PCsB 6 AS 417 stations

B Test StationB 1 PCS 7 server/batch serverB 2 AS417 stationsB 1 Panel PCB 1 OS client

process news 2/2007

14Pharmaceutical industry

COVER

The challenges the pharmaceutical in-

dustry is facing require a partner that

can offer both established industry

knowledge and a broad, versatile, and glob-

ally available portfolio. This partner must

also be in a position to help the industry

meet future challenges.

Siemens has always provided its cus-

tomers with excellent support in this con-

text, having consistently extended and ex-

panded its product line for the pharma-

ceutical industry. Automation solutions

from Siemens have been applied with great

success in the pharmaceutical sector. One

recent example of this is an order from

Janssen Pharmaceutica. The company,

owned by Johnson & Johnson, will use

Simatic PCS 7 in a new chemical develop-

ment pilot plant.

Solutions for API production

Simatic PCS 7 provides comprehensive

functionality for the rapidly growing sector

of biotech production in particular, and

offers a high degree of scalability. The most

recent product is Simatic PCS 7 Lab, which

now enables processes to benefit from a

universal automation platform from the

laboratory to production. In blood fraction-

ation – carried out in part using high-per-

formance systems with more than 20,000

I/O devices – Simatic PCS 7 is applied in

plants of all major players in this segment,

making it the de facto market leader.

Integrated concept for drugmanufacturing

The concept for drug manufacturing com-

bines the efficient automation of diverse

production machines (for example, with

Simatic and Simotion components) with

their simple integration into production

lines and entire plants via systems such as

component-based automation (CbA) and

Simatic IT. The unique flexibility of the hor-

izontal and vertical integration facilitates

the universal control and optimization of

the production processes – a crucial ad-

vantage that increases competitiveness.

Versatile expertise and innovation

Siemens is simultaneously strengthening

itself by acquiring industrial partners that

are specifically certified for work with the

pharmaceutical industry. In order to offer

its customers the best service at reasonable

prices, Siemens has established a partner

program. Siemens is currently working

with approximately 20 partners in Europe,

Asia, and the United States – and this

network will be further expanded in the

future.

Innovation plays a central role in the

pharmaceutical product line. From the

outset, Siemens has supported the devel-

opment of Process Analytical Technology

(PAT) as a key to continuous manufacturing

and, with Sipat, is now making a flexible

platform for PAT available. Tracking and

tracing solutions, with both RFID (radio-

frequency identification) and 2-D matrix

code, are another innovative focal point, as

are solutions for new process variants such

as Siprocess in microreaction technology

and new process concepts using disposable

equipment. This ongoing development of

its product line ensures that Siemens will

continue to be a partner that provides the

right solutions for fitter, faster pharma. �

Find out more:www.siemens.com/pharmaE-mail: cornelia.duerrfeld@siemens.com

Innovation and expertise for the pharmaceutical industry

Fitter, Faster PharmaGrowing with the customer – Siemens has committed itself to this motto for its customers in the pharmaceuticalindustry, and for years it has continued to develop its portfolio of pharmaceutical products, systems, and solutions.

The billboards onTimes Square markingSiemens’ appearanceat Interphex alsounderline Siemens’strong commitment tothe pharmaceuticalindustry in the UnitedStates

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15COVERPharmaceutical Industry

R egulatory and financial forces are

pushing pharmaceutical manufac-

turing toward rapid change. PAT

represents an exceptional opportunity

for pharmaceutical companies to improve

manufacturing performance, reduce man-

ufacturing costs, reduce time to market,

and improve supply chain responsiveness.

PAT allows companies to design quality

into the process and move to real-time

product release.

The scope for process improvement in

many aspects of pharmaceutical manufac-

turing is considerable. The US Food and

Drug Administration (FDA) has noted that

the potential worldwide cost savings from

efficiency improvements could be as high

as US $90 billion, which is equivalent to the

cost of developing 80 to 90 new drugs

every year.

Regulations as a driver for change

The pharmaceutical industry has been slow

to adopt PAT in the past, in large part be-

cause regulation based on off-line batch

inspection slowed progress toward more

innovative continuous in-line manufactur-

ing. Now, however, the regulatory land-

scape has changed. The FDA is engaged in

a major drive to encourage the spread of

PAT as part of its quality initiatives and

cGMPs (current Good Manufacturing Prac-

tices) for the 21st century. The FDA’s PAT

guidance emphasizes the agency’s belief

that significant opportunities exist for

improvement and innovation in pharma-

ceutical manufacturing by moving from

empirically derived trial-and-error meth-

ods to rigorous mechanistically based and

statistically controlled processes.

Part of the PAT approach: Sipat

Siemens has been closely involved in moves

by the FDA and the European Medicines

Agency (EMEA) to encourage the adoption

of PAT in drug manufacturing. Now this

work is being given a boost with the launch

of the new Sipat software that was devel-

oped and piloted by Siemens as part of a PAT

project at the Dutch vaccine institute NVI.

The project, in collaboration with Ap-

plikon Biotechnology and the NVI, and sub-

sidized by the Dutch government, began in

2003. The start roughly coincided with the

release of the FDA’s draft guidance on PAT,

which gave the project both impetus and

wider importance. “This meant that from

the start of the project, the regulatory cli-

mate was rapidly evolving toward a situa-

tion that would allow the exact same ap-

proach to process development and manu-�

Sipat PAT software for pharmaceutical applications

Accelerating Pharmaceutical InnovationSiemens is using its considerable experience in the application of Process Analytical Technology (PAT) in industries suchas food and beverages and the chemical industry to help accelerate change in pharmaceutical manufacturing. With thelaunch of the Sipat software suite, Siemens is applying its expertise to assist pharmaceutical companies in theirimplementation of PAT.

process news 2/2007

16Pharmaceutical Industry

COVER

Vaccine cultivation breakthrough

Using this system, the NVI is now building

a process model addressing all the critical

process attributes for the cultivation of

the Bordetella pertussis bacterium. This

process step is the most critical step in the

manufacturing of a vaccine against whoop-

ing cough. The project team intends to use

the knowledge gained in this project to im-

plement PAT in other cultivation processes

at the institute (e.g., tetanus, diphtheria,

polio), but also in other unit operations

such as freeze-drying. Mathieu Streefland

sums up the initial results: “The project has

given the NVI a head start in the PAT field

for biopharmaceuticals, and we strive to

keep it that way.”

A big leap toward “right first time”

Sipat will significantly assist pharmaceuti-

cal companies in their implementation of

PAT. Sipat is scalable and modular, allowing

controlled growth as a company’s PAT

initiative expands. The software is able to

interface with existing manufacturing ar-

chitecture, allowing full transparency of

quality-related issues from the unit opera-

tion level up to enterprise resource plan-

ning (ERP), manufacturing execution sys-

tems (MES), and laboratory information

management systems (LIMS). With Sipat,

pharmaceutical companies are now able to

achieve greater process understanding,

strive for continuous process improvement,

develop processes based on “quality by de-

sign” principles, and manufacture “right

first time.” The use of Sipat in combination

with the right PAT tools will enable phar-

maceutical companies to improve manu-

facturing performance, reduce manufac-

turing costs, reduce time to market, and

improve supply chain responsiveness. �

facturing control that we wanted to investi-

gate in this project. The outcome is what we

believe the very first automation system

capable of developing and executing full

PAT cultivation processes,” states Mathieu

Streefland, project leader at the NVI.

The Sipat software enables the full inte-

gration of all information flows during pro-

cessing and online comparison of this

process data with historical data. This

means the institute is able to integrate lab

models with sophisticated Near Infrared

(NIR) measurements, as well as data that

are gathered by taking samples, to build a

full process model. The NVI hopes to use

such a model to monitor process perfor-

mance, predict process end points, and, of

course, predict end-product quality.

Find out more:www.siemens.com/sipatE-mail: info.sipat@siemens.com

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The Sipat software enables the full integration of all information flowsduring processing and online comparison with historical data

�

Main benefitsImplementing PAT offers a high return

on investment. Sipat offers significant

business benefits:

B Cost reduction

B Improved quality

B Shorter time to market

B Larger market share

B Improved company image

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process news 2/2007

17TECHNOLOGYProcess Automation

L aboratory experiments are an impor-

tant step in process development and

define central properties of a process

for the large-scale application. Conducting

the experiments necessary for the process

development can already at this stage be

simplified by process automation. A major

prerequisite is that the process automation

be designed, above all, simply and flexibly.

Employees with no special knowledge of

the handling of process control systems

must also be able to add a measuring point

or change a configuration.

Flexible solution

With Simatic PCS 7 Lab, Siemens presents

a control solution for laboratories that is

smoothly integrated into the Simatic PCS 7

process control system environment and

is also flexible and user-friendly.

Simatic PCS 7 Lab uses Simatic compo-

nents so that the control solutions can be

transferred easily during process scale-up.

The system consists of a processing module

based on Simatic PCS 7 Box with automa-

tion, an operator and engineering system,

and an input/output module that acquires

signals from the laboratory instruments

and sends them to the processing module.

More safety, more productivity

With Simatic PCS 7 Lab, the process de-

velopment in the laboratory can also ben-

efit from the advantages of a sophisti-

cated control system. Automated routines

and integrated parameter logging make

the experiments reliably reproducible and

the results safely verifiable. The system

monitors the configured limit values and

reliably triggers alarms when they are ex-

ceeded – but also in other unforeseeable

situations – thereby ensuring greater pro-

ductivity.

Because Simatic PCS 7 Lab also enables

remote monitoring and intervention, the

process technician does not need to be

present. And because the automation

methods are easily transferable, other

processes benefit directly from the pre-

liminary laboratory work in the process

scale-up. �

Simatic PCS 7 Lab: Automation system for experiments in process laboratories

Simple, Modular, and FlexibleWith Simatic PCS 7 Lab, Siemens has developed a control systemsolution that effectively supports development in process engineeringlaboratories. Automatic routines and uncomplicated engineering makeit easier to conduct experiments quickly and reproducibly.

Find out more:www.siemens.com/pcs7www.siemens.com/chemicalsE-mail: walzer.martina@siemens.com

Main benefitsB High reliability with automation

B Reliable control and monitoring ofreactions with integrated managementand safe handling of alarms

B Rapid assembly/reassembly andcommissioning using plug connections

B Simple methods for evaluating measureddata using export features

Simple design: Laboratory instrumentscan be connected to the input/outputmodule using plug connections

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process news 2/2007

18Process Safety

TECHNOLOGY

Operational safety is a centralfunction of process instrumentationand automation in the chemicalindustry. These systems must alsosimultaneously guarantee continuousoperation of the plant. Siemenssupports its customers in fulfillingboth of these requirements byproviding a comprehensive range ofintegrated solutions for processsafety. One example of this support is the Partial Stroke Test for valves.

koep

pel p

hot

oDes

ign

Partial Stroke Test at INEOS Paraform in MainzINEOS Paraform has been using solutions from the Simatic line, including Simatic Safety

Integrated, for some time. At its site in Mainz, Germany, a large formaldehyde plant is

controlled and monitored by Simatic PCS 7.

INEOS Paraform is always looking for innovative ways to further optimize its processes,

increase process safety, and reduce maintenance costs. That is why the company decided

to implement the new Partial Stroke Test (PST) concept from Siemens as a pilot customer.

The concept was implemented at INEOS Paraform’s tank farm in Mainz and subjected

to comprehensive testing. The results of the pilot application were very positive, as

confirmed by Richard Frey, who is responsible for monitoring and control technology:

“By reducing the time spent on the annual tests of the safety circuits, we see excellent

application opportunities for this solution, in particular at our continuously operating

plants, where downtime is infrequent and brief.”INEOS Paraform is the pilot customerfor the Partial Stroke Test concept

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The Partial Stroke Test as a module in the process safety concept

ExtendingMaintenanceIntervals

process news 2/2007

19

To ensure reliable, safe operation,

chemical production plants are fitted

with safety integrated systems (SIS).

In the case of a fault, these systems prevent

plant damage and the release of hazardous

materials. These SIS must undergo rela-

tively costly function tests at regular inter-

vals. These tests interrupt the continuous

operation of the plant.

Plant operators are therefore always

looking for opportunities to extend these

test cycles without compromising plant

safety. These testing requirements are par-

ticularly relevant to actuators within safe-

ty technology, as this is where both the

greatest risks and the greatest potential for

rationalization can be found. A typical ex-

ample is the stop valves that prevent the re-

lease of hazardous substances (e.g., toxic

fluids or gases).

Function testing during operation:Partial Stroke Test

In practice, many of these valves are rarely

closed. Over time, the friction increases,

particularly the breakaway torque of shear

valves or the initial breakaway torque of

pivot fittings, due to corrosion or increas-

ing scaling on the shaft or the interior fit-

tings. This means that when the safety

valves are used in an emergency, they of-

ten lock.

A so-called Partial Stroke Test (PST) at

specified intervals can effectively prevent

such malfunctions. This test typically in-

volves moving the fittings by around 10 to

15 percent. This process does not interfere

Main benefitsB No need to dismantle the fittings

from the plant

B Extended maintenance intervals

B Following a successful PST, the fittingsare cleaned as well: caking and scalingare removed

B High reliability in emergencysituations: fittings do not lock up, no response delay

B Simple online function controlwithout disrupting the processes

B Faults can be detected early

B Cost savings due to lowermaintenance expenditure and less downtime

IEC 61508With PST (4x/year)Proof tests all

2 years = SIL 2

SIL 1

SIL 2

SIL 3

SIL 4

PFD(t)

PFDavg

TimeProof test interval

Without PSTProof tests

Annual = SIL 2

Test intervals can be extended using the Partial Stroke Test

In addition tonumerousdiagnosticfunctions, theSipart PS2intelligentpositioner alsooffers integratedPartial StrokeTest functionality

measure of the mobility of the fitting.When

a valve is commissioned, the response time

is saved as a reference value for the PST.

This value is later used for comparison pur-

poses.

The maintenance requirement is clearly

and concisely signaled to the user with a

OK (no maintenance request)

Maintenance request

Priority maintenance request

(Imminent)

failure of the instrument

Fault

code

Current

position

Priority of

maintenance request

In the three-stagealarm concept formeasuringtransducers inaccordance withNAMUR recom-mendation NE107,three color-codedsymbols makeclear the priorityof the main-tenance request

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with the operation of the plant but does

demonstrate the mobility of the fittings.

Intelligent and integrated: Sipart PS2

The Sipart PS2 intelligent positioner mea-

sures the reaction of the valve during the

PST. It uses the venting time as a reliable �

process news 2/2007

20Process Safety

TECHNOLOGY

three-stage alarm concept for measuring

transducers in accordance with NAMUR

recommendation NE107. Operating per-

sonnel can start the PST with Sipart PS2 in

four different ways: via the process control

system or the Simatic PDM process device

manager, via the front buttons on the Sipart

PS2 control panel, via the binary input of

the device, or by parameterizing particular

cyclical time intervals in the device.

Flexible test functions with Simatic S7-400FH

In addition to the PST with the Sipart PS2

positioner, Siemens offers integrated PST

functionality for the Simatic S7-400FH safe-

ty system as an add-on product. Preconfig-

ured logic for the execution of the PST, as

well as the optional solenoid valve test, is

supplied for the S7-400FH protection sys-

tem as well. The associated screen module

for the Simatic PCS 7 OS user interface pro-

vides a rapid overview of the status and

alarms, permits access to configuration pa-

rameters, provides the status of the last

PST, and has a command interface for start-

ing and breaking off the PST.

The test can be started manually, auto-

matically, or on request, and comprises

two stages. In the first stage, the actual

PST/valve startup test, a safety stop valve is

moved from the fully open position (oper-

ating position) to a defined set point by the

S7-400FH safety system via the additional-

ly fitted positioner system. The closing

process must reach the set point with the

defined hysteresis within the specified test

time. Once the test time has expired, the

safety stop valve is returned to the fully

open position (operating position). In an

optional second step, the associated sole-

noid valve can be tested.

Integrated module of the Simaticprocess safety concept

The integration of test processes for valves

into the control system, either via the Sipart

PS2 intelligent position controller or as an

integral variant for the Simatic PCS 7 pro-

tection/process control system, significant-

ly simplifies the execution of safety-ori-

ented tests. By automating the procedure,

including the comprehensive documenta-

tion of progress, which previously had to

be done manually, quality has increased

markedly while costs have simultaneously

fallen.

The solutions for the PST are only one

module in Siemens’ comprehensive process

safety concept. In order to provide users

with optimal support for all safety features

throughout the entire life cycle of their

systems, Siemens offers a complete range

of integrated solutions for process safety. A

key component of this is the Simatic Safety

Matrix, which addresses the entire safety

life cycle, from analysis to implementation

to operation. This package of software

tools, hardware components, and services

for fault-free process control technology

ensures maximum operational safety and

optimal plant operation in all phases of the

plant life cycle. �

Find out more:www.siemens.com/chemicalswww.siemens.com/processinstrumentationE-mail: alexandre.bouriant@siemens.com

klaus-peter.heer@siemens.com

Standards for functional safetyIn the process industry, applications, materials, or reactions sometimes require partic-

ular safety measures to mitigate risks to the plant, personnel, and the environment.

Automation technology components are now increasingly being used for these mea-

sures. The correct operation of these systems and components is collectively referred

to as functional safety. The conditions for the use of such systems are specified in two

standards: IEC 61508 and IEC 61511.

IEC 61508 is the basic standard for the safety standards. As an application-oriented

standard for the process industry, IEC 61511 is a standard used in the planning,

implementation, and operation of safety systems in process systems. These systems,

comprising controllers, sensors, and actuators, ensure that the status of the process

remains safe should defined limit values be exceeded.

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s

Safety shutoff with positioner

Industrial Ethernet

AS: S7-400FH

Protection

Set-point valve positioning

Feedback valve positioning

Solenoid valve/control valve

PCS/OS for:B Operation/monitoringB AlarmsB ArchivingB Printing reports

S7-400FH:B Partial Stroke TestB Solenoid valve testB Interface to OS

Air supply

ES OS

The PST with Simatic S7-400FH and Simatic PCS 7 checks all function-criticalcomponents of the stop valve, triggers an alarm in the control system if necessary,and offers report functions

�

Advanced ProcessControl ensuresconsistent productquality in manyareas of industry,for example, the glass or thechemical industry

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process news 2/2007

21TECHNOLOGY

Find out more:www.siemens.com/pcs7www.siemens.com/glassE-mail: walzer.martina@siemens.com

Advanced Process Control

T oday, traditional proportional-inte-

gral-derivative (PID) control is the

workhorse in automated plants, sim-

ply because those controllers are so easy to

implement and operate in control systems.

However, very often PID loops do not oper-

ate at the engineered point, or operators

simply switch them to manual control

when the control quality achieved does not

match expectations.

Adapt to optimize

An alternative that solves these problems is

the adaptive PID controller. It works on the

basis of a process model that is executed in

the background to determine the results of

an operator interaction, thus evaluating

and predicting results – for example, to

forecast the process temperature when

opening a steam valve to a certain extent.

Or – vice versa – it identifies and applies the

valve setting required to achieve or main-

tain a defined temperature.

Another step forward

However, adaptive PID control cannot deal

effectively with more complicated process-

es. Multivariable and predictive controllers

(MPCs) overcome the limitations of tradi-

tional control. These controllers simplify

complex plant dynamics and permit early

elimination of faults based on artificial in-

telligence and model-based control. These

mathematical tools are complemented by

process knowledge and project experience

to generate a plant “autopilot” that is able

to keep the installation operating at its best

for long periods of time, thus optimizing

costs and ensuring that quality is within

the defined limits. Additionally, it provides

for complex process control. Both con-

troller models are included as add-ons in

the Simatic PCS7 control system. The han-

dling of complex plant dynamics is drama-

tically simplified, thus eliminating costly

trial-and-error procedures.

Freedom to choose

In the area of adaptive as well as multivari-

able/model-predictive control, Siemens col-

laborates with companies implementing

their expertise in advanced products. These

solutions ensure high performance control

by keeping relevant variables within a

small band, offer automated and flexible

process operations by obtaining predictive

and reproducible results, and provide con-

tinuous optimization by minimizing ener-

gy and raw material consumption. �

Advanced Process Control solutions increase process controllability

Focus on ControlApplying model-based advanced control strategies for processoptimization is a prerequisite for better exploiting plant potential.Advanced Process Control (APC) helps customers in many industrieswith dedicated applications better control their processes.

Main benefits

B The handling of complex plant

dynamics is dramatically simplified,

eliminating costly trial-and-error

procedures

B Advanced methods directly address

the reduction of process variation and

optimize tuning procedures, therefore

leading to significant cost reduction

process news 2/2007

22Sugar Industry

CASE STUDY

The production process at SüdzuckerAG in Rain am Lech, Germany, runsaround the clock during the sugarcampaign from September toDecember because the sugar beetsmust be processed as quickly aspossible to achieve the highestpossible sugar yield. “All systems must work perfectly,” explains Günter Leinfelder, chief electrician atSüdzucker in Rain, “and that includesthe preparation of the water used forunloading and cleaning the beets.”Efficient motor management,achieved with Simocode, has recentlybeen ensuring availability in thisprocess section.

The sugar beets are rapidly unloaded

from the arriving trucks with a high-

pressure water jet and at the same

time precleaned. The water required for

this runs in a circuit and is continuously re-

circulated. However, the process also cre-

ates a water surplus, which is treated in the

factory’s own sewage plant. In addition to

an anaerobic and an aerobic stage, the plant

contains so-called oxidation ponds in which

oxygen is added to the wastewater.

These ponds are ventilated by air jets.

Every jet is supplied with air by its own fan,

which is driven by a conventional three-

phase-current asynchronous motor with a

power of 15 to 30 kilowatts. A new feature

at Südzucker in Rain is a motor manage-

ment system that allows the control and

monitoring of every individual fan from a

central control station. Südzucker chose

Simocode pro V because this solution al-

lows the motor functions to be monitored

directly on-site at any time from the central

control station.

Rapid replacement of equipment

In order to ensure an uninterrupted pro-

duction process during the critical cam-

paign phase, Südzucker was looking for a

solution that would enable rapid, easy

equipment replacement without affecting

the ongoing production process – a de-

mand that could be met with Simocode pro.

A special memory module mounted on the

basic unit serves to enter, trace, and record

all the parameter settings, so that when the

motor management system needs to be

Motor management with Simocode ensures systemavailability at Südzucker

Reliable at Full LoadThe sugar beets are unloaded from the arriving truckswith a high-pressure water jet

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process news 2/2007

23

but we have never been able to do this until

now.”

But Simocode pro can do much more be-

sides. In addition to analyzing the current

drain, a version of the controller is also

available that measures the voltage curve in

the main circuit and is therefore able to

process and monitor power-related mea-

surement variables in the device. With a

temperature module, it is also possible to

monitor the current temperatures of the

drives and display these values at the con-

trol station. An extension module for ana-

log signals between 0.4 and 20 milliam-

peres is also available, with which levels,

positions, or flow values, for example, can

be measured.

Preemptive maintenance

Simocode pro also enables calculation of

the actual active power of the drive by

measuring the cos phi power factor. The

plant owner can therefore keep an eye on

the aging of the fan drives and decide, be-

fore the annual campaign begins, whether

a drive has to be changed for reliability

reasons.

Südzucker’s aim was to set up an exten-

sive energy management system with the

possibility of switching every drive on and

off individually. Simocode pro’s ability to

transfer all measured values continuously

to the control station at cyclic intervals and

trigger an alarm when faults are detected is

a great benefit to the company. Every drive

is combined with 3RT contactors and 3RV

circuit breakers for remote control of the

fan drives.

Status information and fault messages

are not only displayed in the control center

but can also be directly visualized locally at

any time. To do this, a special operating

module simply has to be plugged into the

control unit. The compact unit, which has

four freely assignable keys and seven freely

applicable LED indicators, allows critical

operating and control functions to be per-

formed directly on-site, making a major

contribution to speed and flexibility in the

elimination of technical problems.

Fit for the next heat

For Leinfelder, the functionality of

Simocode pro is a great improvement be-

cause the availability of the water treatment

system can be guaranteed even while the

sewage plant is operating under full load

for several months. “Like athletes, we have

to consistently use the best equipment to

stay fit for the next heat in the race,” he

says of Südzucker’s decision to implement

the latest motor management technology

from Siemens. �

Find out more:www.siemens.com/simocodewww.siemens.com/sugarE-mail: simone.witzgall@siemens.com

guenter.losert@siemens.com

Simocode pro: Smart, flexible andsophisticatedB Extremely rapid replacement of

the control unit, enabled by theremovable module for operating-parameter storage

B Open Profibus DP communication formeasuring data and alarm messages

B Pluggable operating module for localmonitoring and control

B Monitoring of drive aging throughcalculation of the current activepower

B Optional modules for temperaturemonitoring and input/output ofanalog signals

B Measuring of the current and voltagecurve to monitor performance-relatedmeasurement variables

The sugar refinery in Rain am Lech Sirius protection and switchingdevices are also used in Rain

changed, the operator simply removes this

module and mounts it on the replacement

device. The system can then continue op-

eration immediately, with the same pa-

rameter settings. Leinfelder is delighted:

“Changing the memory module takes only

about 30 seconds. That’s just what we need,

process news 2/2007

T he new Siflow FC070 Coriolis flow-

meter takes the idea of Totally Inte-

grated Automation right down to

the process instrumentation level. This

compact device is designed for direct in-

tegration into Simatic systems, enabling

multiple parameters to be measured in

gases and liquids. Siflow FC070 covers a

broad spectrum of flow applications for

the majority of gases and liquids and is

easy to install.

Thanks to its seamless integration into

Simatic, the device is easy to configure,

which reduces the level of complexity in a

plant. Siflow FC070 diagnoses the plant sta-

tus and has standard interfaces to Simatic

Manager, PCS 7, and Simatic PDM. It is also

available as an independent unit capable of

exchanging data with devices from third-

party vendors via Profibus or Modbus.

The device simultaneously monitors flow,

temperature, density, and volumetric flow

as well as fractional flow with an error of

less than 0.1 percent, making it well suited

for all industry applications in which accu-

rate flow measurement is essential.

Robust flowmeter

The high-performance Sitrans FUS060

ultrasonic flowmeter is specially designed

for industrial plants that require robust

devices and rely on fault-resistant measur-

ing components – for example, in the oil-

refining industry, petrochemical plants,

power station systems, or wastewater pu-

rification plants. Sitrans FUS060 is pre-

pared for the OIML R117 standard and can

be used in all respective applications.

The certified instrument has a HART in-

terface and can be operated either with two-

jet technology or with four-jet technology

for higher performance and accuracy. The

FUS060 transmitter offers fieldbus com-

munication via Profibus and is PDM com-

patible. Its die-cast aluminum housing is

designed with an IP65/NEMA4 enclosure

rating.

Level measurement transmitter for challenging applications

The new Sitrans LR460 radar level mea-

surement transmitter is based on the Sitrans

LR400 device and can measure virtually any

solid medium, including cement powder,

fly ash, coal, gypsum, flour, grain, aggre-

gates, and plastics. The transmitter is par-

ticularly suitable for continuous level mea-

surement in difficult solids applications with

extreme dust or high temperatures. Sitrans

LR460 features 24-gigahertz FMCW (fre-

quency modulated continuous wave) tech-

nology with advanced Process Intelligence

echo processing. The 24-gigahertz wave-

length can create a stronger signal than

New products for process instrumentation

Innovative,Robust, andVersatileSiemens has expanded its product portfolio in the field of processinstrumentation. New flowmeters as well as a new level measurementtransmitter, weighing instrument, and temperature transmitter open upnew areas of application, function well in difficult process conditions,and provide additional automation options.

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The robust, high-performance SitransFUS060 ultrasonic flowmeter

Range of up to 100 meters: SitransLR460 level measurement transmitter

The Siflow FC070 Coriolis flowmeteris designed for direct integration withSimatic S7

24Process Instrumentation

TECHNOLOGY

process news 2/2007

and wastewater plants. As a complete solu-

tion, the device contains general PLC pump

station functions in a single preconfigured

unit. Sitrans LUC500 replaces the Milltron-

ics EnviroRanger ERS 500, maintaining the

same proven features and benefits.

Sitrans LUC500 combines noncontact-

ing ultrasonic technology, echo-processing

techniques, and proven application soft-

ware to provide accurate level control of

liquids in wet wells up to 15 meters deep. It

also monitors flow in flumes, weirs, and

5.8-gigahertz technology, so the instru-

ment has a long range of up to 100 meters.

After initial setup, the Process Intelligence

software responds automatically to chang-

ing material slope conditions and physical

silo features such as fixed obstructions or

buildup.

Complete solution for pump stations

Sitrans LUC500 integrates advanced ultra-

sonic level control and monitoring for du-

plex lift stations run by operators of water

New micro gaschromatographThe new Sitrans CV natural gas chromatograph featuresfast, precise, and reliable determination of calorificvalues. The main area of application for the micro-technology-based Sitrans CV is in the natural gasindustry, especially for tasks with mandatory calibra-tion, such as pipeline monitoring, gas transfer anddistribution stations, and LNG (liquefied natural gas)

terminals, where gas is liquefied or converted back to gas. The compact device with arugged, explosion-proof housing is suitable for extreme ambient conditions of –20 to +55degrees Celsius. It can be mounted near natural gas pipelines, provides complete informa-tion on the natural gas quality, and delivers the measuring results in less than three min-utes. The new device has already impressed the first customers. After exhaustive tests in itscentral test and calibration laboratory, the largest oil and gas drilling and productioncompany in Poland, Polskie Gornictwo Naftowe i Gazownicto (PGNiG), recommendsSitrans CV for the analysis of natural gas in Polish networks. The tests concentrated on therepeatability of the measuring results, any memory effects, the influence of the ambienttemperature on the precision of Sitrans CV, and pressure fluctuations in the sample supply,using test gas concentrations typical for natural gas. The results of the tests were com-pletely positive. PGNiG was particularly impressed by Sitrans CV’s short analysis times, lowcosts, and MEMS (micro-electro-mechanical systems) analysis technology.

The new Milltronics MBS belt scaleoperates without a cross-bridge

Sitrans LUC500: Integrated unit forlevel monitoring and control induplex lift stations

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The Sitrans TH 400 head transmitter isavailable in versions for Foundationfieldbus and Profibus PA communication

Find out more:www.siemens.com/processanalyticsE-mail: michael.markus@siemens.com

other open channels. The device improves

efficiency and reduces energy consump-

tion and maintenance costs by decreasing

pump failures and site visits.

Belt scale for continuous weighingreliability

The new Milltronics MBS belt scale for reli-

able, continuous weighing is a modular

system for medium-duty applications. It is

suited for applications involving aggre-

gates, sand, gravel, or crushed stone. This

new belt scale does not have a cross-bridge,

which reduces material buildup and allows

universal fit on most conveyor widths.

When combined with a Milltronics BW100

integrator and a Milltronics TASS speed

sensor, the system provides a dependable

and economical belt scale package.

Fieldbus-compatible head transmitter

Finally, there is also a new transmitter for

temperature measurement: the fieldbus-

capable compact Sitrans TH 400, which ex-

tends the series of Sitrans TH head trans-

mitters. The instrument is available in ver-

sions for Foundation fieldbus and Profibus

PA communication and can also be used for

simple control jobs in a Foundation field-

bus segment. This development stresses

Siemens’ commitment to innovation in all

fields of process instrumentation. �

Find out more:www.siemens.com/processinstrumentationE-mail: sigrun.ebert-heffels@siemens.com

25

process news 2/2007

26Breweries

CASE STUDY

The Ziemann Group has an excellent

reputation in the brewing industry

for its ultra-precise brewing solu-

tions. High quality and continuous R&D are

the distinguishing characteristics of this

company, which has been using Siemens

automation technology for decades. In June

2006, Ziemann commissioned a one-of-

a-kind pilot plant at its headquarters in

Ludwigsburg, Germany. It can reproduce

all conventional brewing processes on the

market on a smaller scale, and its automa-

tion technology is state of the art.

The primary purpose of the plant is to test

new technologies under live operating con-

ditions. The miniature brewery is equipped

with the same technology as large-scale

plants. It uses Braumat process control

technology based on PCS 7 and operates

down to the field level with Siemens com-

ponents. At just 100 square meters, the

small-scale brewery plant has all the fea-

tures of a full-grown brewhouse and can be

run in a fully automated manner via the

Braumat PCS 7 process control system. “We

want to use the pilot plant to develop opti-

mized processes, put new components such

as the Sitrans P300 pressure transducer to

the test, and carry out R&D together with

our business partners,” explains Dr. Hans-

Jörg Menger, manager of development and

technology at Ziemann.

On the open brewing tanks, a pressure

transducer measures the static pressure of

the liquid column and from that value de-

termines the level. The level in the closed

tanks of the fermentation and storage ves-

sels is monitored with two pressure trans-

ducers.

SIP and CIP as hygiene benchmarks

Hygiene is essential in the food and bever-

age industry, so all measuring instruments

must satisfy stringent hygiene require-

ments and, for example, be SIP (steriliza-

tion in place) and CIP (cleaning in place)

compatible – requirements that the Sitrans

P300 easily fulfills, thanks to the extreme-

ly hygienic design of its stainless steel

housing. “In the P300, even the analysis

electronics are encapsulated in stainless

Braumat PCS 7 and Sitrans P in brewery pilot plant

PilotMicrobreweryThe Ziemann production engineering company optimizes the brewingprocess and tests new components at its new pilot plant, a completebrewery on a small scale. The pilot plant is automated with BraumatPCS 7 and uses integrated technology from the Totally IntegratedAutomation line. One of the components used is the new Sitrans P300pressure transducer, developed especially for the food and beverageindustry. Ziemann tested the suitability of the transmitter for thebrewing industry.

The Sitrans P300 pressure transducer with a stainless steelhousing is characterized by an extremely hygienic design

Sitrans P300 pressure transducerB Hygienic design in accordance with SIP and CIP benchmarks

B Stainless steel housing with encapsulated electronics

B Intelligent design with front-flush measuring cell for measurementwithout dead space

B Temperature up to 150°C, with temperature isolator up to 250°C

B High long-term measuring precision (measurement deviation of 0.075%max., long-term drift of 0.25% in 5 years)

B Simple local and remote parameterization

B Comprehensive diagnostic functions and status messages for increasedsystem availability

process news 2/2007

27

acterized by long-term stable measuring

performance. The low measurement devi-

ation enables processes to be run even clos-

er to the optimal level of efficiency, there-

by increasing system productivity.

The transmitter can be integrated into

the production plant using all regular

thread types. Moreover, various hygienic

connections with front-flush membranes

fulfill the requirements of a process con-

nection free from dead space. A laser weld

seam joins the transducer connection with

the measuring cell membrane with a high

surface finish, eliminating the need for a

seal on the process side. This will prevent

the buildup of product deposits and the

possible growth of bacteria. Surface rough-

ness in accordance with the standards of

the European Hygienic Equipment Design

Group (EHEDG) is guaranteed for all com-

ponents and weld seams that come into

contact with the process medium.

Pressure transmitters are often used for

process media at temperatures that exceed

150 degrees Celsius. These devices provide

the required temperature decrease be-

tween the process and electronics. In such

cases, the membrane of the pressure trans-

mitter is located in front of the membrane

of the measuring cell, with the result that

this technology is associated with limited

measurement accuracy. The Sitrans P300

uses a temperature isolator, providing both

a cost-effective solution and unlimited

measurement accuracy.

Simple parameterization

The Sitrans P300 pressure transducer can

be installed and operated either directly

on-site or parameterized via the control

system. According to Gerhard Lillich, one

of its most positive and user-friendly func-

tions is that addresses can be adjusted lo-

cally on the devices: “It is a definite bene-

fit for us and saves considerable time.”

In addition, the simulation of ramp func-

tions via HART or Profibus PA simplifies

commissioning. A current sensor with an

output of 4–20 milliamperes was imple-

mented in the P300 especially for the com-

missioning of measuring circuits. The ver-

satile diagnostic functions of the status mes-

sages generated in the cyclical exchange of

data facilitate the analysis of faults, thereby

contributing to reduced downtime and in-

creased plant availability overall.

Lillich has great confidence in the de-

vice: “We have been using the Sitrans P300

for only a few weeks, so we have no long-

term experience, of course. However, we are

very satisfied with its stability and temper-

ature resistance. There have been no faults

to date and we are very taken with the de-

vice. Above all, the parameterization via the

control system for changes to the produc-

tion process really is an excellent idea.” �

Find out more:www.siemens.com/brewerieswww.siemens.com/processinstrumentationwww.siemens.com/sitranspE-mail: ruediger.selig@siemens.com

frank.sass@siemens.com

steel,” explains Gerhard Lillich, deputy

manager of development process automa-

tion at Ziemann.

The front-flush measuring cell therefore

meets the optimal requirements for mea-

surement without dead space and also

makes cleaning much easier. With a speci-

fied temperature range of up to 150 de-

grees Celsius, the pressure transducer

withstands sterilization in place without

drift.

Long-term measurement stability

The Sitrans P300 pressure transmitter,

which has a measurement deviation of a

maximum of 0.075 percent and long-term

drift of 0.25 percent over five years, is char-

The new pilot plant atZiemann represents ascaled-down versionof the completebrewing process; it isequipped andautomated like alarge-scale plant

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The Sitrans P300 isused in the pilotplant to measurethe pressure in theclosed vessels

process news 2/2007

28Sensors

CASE STUDY

W ith a staff of 1,600, Zentis is not

only one of the largest German

jam and preserves manufactur-

ers; it also supplies cereals, raw marzipan,

sweet bars, and marzipan eggs to the food

processing industry and retailers. The 190

employees at the Factory II in Aachen-

Eilendorf alone produce approximately

12,000 tons of sweets per year.

The company’s internal logistics were

reorganized to clearly identify the origin

and route of the products, both during and

after production. “Many of our customers,

especially discount stores, are demanding

that the outer packaging no longer carry

the normal EAN or UPC codes to avoid po-

tential conflicts with the codes of the goods

management systems and the associated

problems at their scanner cash registers,”

explains Achim Minten, the European

maintenance manager responsible for au-

tomation at Zentis Factory II. “We therefore

print the boxes with a data matrix code that

can be read, decoded, and evaluated by

camera systems.” The 12-by-12-millimeter

dot matrix contains the production line, the

assignment of the palletizing station, and

the article number.

Automatic and reliable performanceeven at high speeds

A special solution for detecting the DMC at

the end of the production lines was needed

where the goods are packed in automati-

cally assembled boxes and conveyed to the

palletizing stations via various rails. To re-

liably identify the boxes before discharging

them to the assigned station, the manufac-

turer chose Simatic VS130-2 vision sensors.

Three important factors supported the use

of this solution: the convincing perfor-

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Vision sensors optimize company logistics at Zentis

An Eye for DetailProcesses in the food industry operate with a high degree of automation.Consequently, even the outer packaging of foods must be labeledaccording to certain specifications. No EAN (European Article Number)codes may be used, for example, on outer packaging because thesecould cause problems in customers’ goods management systems. Outer packaging at Zentis in Aachen, Germany, is therefore identified by data matrix codes (DMCs) that are read quickly, automatically, andreliably by vision sensors.

The boxes at Zentis in Aachen are identified by data matrix codes to avoid conflictsin end customers’ goods management systems

process news 2/2007

29

al interface boxes or converters. Besides,

the configurer can access the processing

unit, change the parameterization, or call

and activate one of the 15 storable param-

eter sets directly from any terminal in the

network.

The conveyor system itself is controlled

by a highly available Simatic S7-400H con-

troller and visualized by a WinCC user in-

terface. A status census, that is, how many

boxes of a palletizing order have already

been detected, is displayed in addition to

the data detected by the camera. The census

criteria to be evaluated are freely definable.

Considerable improvements

The new code-reading systems have clear

advantages over the previous solution in

ongoing operation. “With the new system

we were able to improve both our logistics

and our quality assurance,” says Minten,

“because the DMC labeling allows tracking

of the products to the individual machine

and the respective batch. The cause of the

error and route of the affected products can

therefore be traced quickly in the event of

complaints.” Before the new system was in-

troduced, the box data had to be entered

manually and noted on a pallet slip, and

great additional effort was also required

for consistent data acquisition during pro-

duction.

Zentis is using four Simatic VS130-2

vision sensors at the Factory II in Aachen-

Eilendorf at the moment. They have all

been working to the user’s complete satis-

faction since being commissioned, and the

use of further systems in the area of the

four existing box assemblers is already

planned. The boxes are printed with a DMC

according to the requirements of the pro-

duction lines before assembly; this DMC is

read automatically and controls the distri-

bution of the assembled box to the appro-

priate production line. This increases pro-

ductivity and reduces the risk of error. �

Find out more:www.siemens.com/simatic-sensors/mvE-mail: info.simatic-sensors@siemens.com

mance of the camera system at high through-

put speeds, the support from Siemens in

developing a solution suitable for this in-

dustry, and time- and cost-saving unifor-

mity in conjunction with the existing au-

tomation technology. “Most of the systems

are very familiar to us,” says Minten, “and

the necessary know-how is usually passed

on in a single on-the-spot training session.

The uniformity of the Siemens technology

in configuration, data storage, and com-

munication makes work easier for our en-

gineering department in all areas, from set-

up to modifications to rapid troubleshoot-

ing – even without external help. Another

decisive advantage of the image processing

system is that the processing unit has both

a Profibus and an Ethernet interface.”

This approach completely eliminates

typical interface problems due to addition-

Simatic VS130-2 vision sensors at ZentisB Reliable reading processes at travel speeds of 0.7 m/s

B Reliable identification of DMC codings on different surfaces

B Variable reading distances of 75 to 3,000 mm, depending on the lens

B Variant with C or CS-Mount sensor head and protective housing with a front panel

of unbreakable plastic, in compliance with the International Food Standards (IFS)

regulations regarding the use of glass in food production

B CCD sensor with a resolution of 640 pixels x 480 pixels that compensates system-

related fluctuations (e.g., positioning, trigger inaccuracy, and printing position)

B Automatic adaptation of the read algorithms, providing a reliable reading

result despite focus and size fluctuations

B Control of the circular lighting unit by the processing unit of the VS130-2

in sync with the image feed, allowing an exposure time of 20 µs to 10 ms

at maximum light intensity

B A processing unit with both a Profibus and an Ethernet interface

The Simatic VS130-2 sensor is equipped with a circular lightingunit, which provides optimum illumination

An eye on the production: The status of the process and ordersis visualized by Simatic WinCC

process news 2/2007

30Process Instrumentation

CASE STUDY

Univar is a world leader in industrial

chemical distribution, with a net-

work of 163 distribution hubs in

North America and Europe. The company

processes, blends, and repacks bulk chem-

icals for specific customer needs. The depot

at Wellingborough in the UK supplies cus-

tomers in all industry sectors throughout

the UK. The site has 17 vertical cylindrical

tanks storing a range of chemicals.

Noncontacting solution

In November 2005, the local engineering

firm Stratos replaced the existing hydro-

static device with a Sitrans LR200 radar

transmitter. Each new radar instrument

was installed in a nozzle on top of the tank,

outside the tank wall. The microwaves pass

through the tank roof, so the devices are

never directly exposed to the chemical con-

tents. This innovative installation required

no drilling, and instruments can be re-

moved without emptying the tank. In addi-

tion, all tanks except the water tank were

equipped with a Pointek CLS100 capaci-

tance high-level switch as a fail-safe against

spills. These are also installed externally.

All instruments are wired into a Simatic

S7-300 PLC and a Simatic HMI panel. The

high-point level system is designed to

sound an alarm if the tank reaches a set

point, and the graphic display provides vi-

sual cues to indicate whether the tanks are

full, empty, or at normal levels.

Improved stock control

Because of the aggressive chemicals, non-

contacting radar proved the right technol-

ogy choice for these applications. Jez Hill,

regional engineering manager at Univar,

says, “The noncontacting approach reduces

the maintenance, which saves us a lot of

staff hours and downtime. We have great

confidence in the system.” �

Univar enhances operationswith new level system

SafeControlSince the Univar depot at Welling-

borough in the UK was commissioned

in 1988, process equipment such as

the hydrostatic level system had

become obsolete and needed

replacing. The hydrostatic transmitters,

inserted at the bottoms of the tanks,

were difficult to install and had to be

removed for regular calibration.

Because they were in direct contact

with corrosive chemicals, they needed

frequent cleaning and replacement.

Each time, this required emptying the

tank, causing downtime of up to two

days. Noncontacting level devices from

Siemens solved this problem.

Find out more:www.siemens.com/levelE-mail: rob.niezen@siemens.com

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Main benefitsB External installation and noncontacting

measurement for increased reliability

B Easy-to-use central HMI with high-

point alarm system improves stock

control and operational safety

A Sitrans LR200 radar transmitter mounted on top of the tank provides continuouslevel measurement, while a Pointek CLS100 capacitance switch provides a high-level fail-safe; both instruments are installed outside the tank wall

The Simatic HMI panel providesthe status of each tank, with visualcues indicating level measurement

for increased reliability

Sitrain courses for Simatic PCS 7and process analyticsIn parallel with the introduction of the new Simatic PCS 7 Version 7,

Sitrain is offering an optimized-upgrade course as well as a 10-day

system course. The purpose of the 3-day upgrade course is to com-

municate to users already familiar with Simatic PCS 7 the new engi-

neering options available in Version 7, using examples. In the 10-

day system course, participants will learn about Simatic PCS 7 Ver-

sion 7 beginning at the very beginning and will learn how to apply

the variety of engineering functions effectively. Another sequence

of foundation courses will start in the fall of 2007.

In total, Sitrain has recently incorporated 22 new courses on

process analytics into its program. The training covers a wide range

of products, from Ultramat and process gas chromatographs such

as MicroSAM and Maxum edition II to applications for customer-

specific process gas analysis.

Information on training courses covering Simatic PCS 7:

www.siemens.com/sitrain-pcs7

Information on training courses covering process analytics:

www.siemens.com/sitrain-sc-pa

infoinfoDo you want to know more about the systems and solutions for

the process industry from Siemens Automation and Drives?

Simply visit our information portal on the Internet at

www.siemens.com/processautomation

onlineonline

events

www.siemens.com/processnews

Here you can download the current issue and past issues of

Process News in PDF format, or search directly for articles about

specific topics, technologies, and systems in the Reference Center.

events

31DIALOGUE

process news 2-07PublisherSiemens Aktiengesellschaft

Bereich Automation and Drives (A&D)

Gleiwitzer Str. 555, 90475 Nuremberg

Germany

www.siemens.com/automation

Group Executive ManagementHelmut Gierse, Hannes Apitzsch,

Dr. Peter Drexel, Anton S. Huber

Responsible for ContentPeter Miodek

Responsible for Technical ContentCornelia Dürrfeld

ConceptChristian Leifels

EditorCornelia Dürrfeld, Siemens AG, A&D CC P MC

Siemensallee 84, 76187 Karlsruhe, Germany

Tel.: +49 (0) 7 21 5 95-25 91

Fax: +49 (0) 7 21 5 95-63 90

cornelia.duerrfeld@siemens.com

Editorial CommitteePetra Belzner, Alexandre Bouriant,

Sigrun Ebert-Heffels, Michael Gilluck,

Birgit Gottsauner, Walter Huber, Bernd Langhans,

Silvana Rau, Rüdiger Selig, Wieland Simon,

Roland Wieser, Wolfgang Wilcke, Eugene Yeo

Publishing HousePublicis KommunikationsAgentur GmbH, GWA

Corporate Publishing, Medien 1

P.O. Box 3240, 91050 Erlangen, Germany

Tel.: +49 (0) 91 31 91 92-5 01

Fax: +49 (0) 91 31 91 92-5 94

publishing-magazines@publicis-erlangen.de

Editor in chief:

Kerstin Purucker

Layout:

Jürgen Streitenberger

Copy editing:

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DTP: der Döss für Kommunikation, Nuremberg

Printed by: Stürtz GmbH, Würzburg

process news is published quarterly.

Circulation: 34,000

Job number: 002800 581

© 2007 by Siemens Aktiengesellschaft

Munich and Berlin, Germany

All rights reserved by the publisher.

This edition was printed on environ-

mentally friendly chlorine-free paper.

ISSN 1430-2292 (Print)

The following products are registered trademarks of Siemens AG:BRAUMAT, DESIGO, MicroSAM, MILLTRONICS,

POINTEK, S7-300, S7-400, SIFLOW, SIMATIC,

SIMATIC HMI, SIMATIC IT, SIMATIC PCS 7,

SIMATIC Panel PC, SIMATIC Safety Integrated,

SIMOCODE, SIMOTION, SINAMICS, SIPAN, SIPAT,

SIPART, SIPROCESS, SIRIUS, SITRAIN, SITRANS,

SIWAREX, TELEPERM, TOTALLY INTEGRATED

AUTOMATION, ULTRAMAT, WinCC

If trademarks, trade names, technical

solutions, or similar are not listed above,

this does not imply that they are not

registered.

The information provided in this magazine

contains merely general descriptions

or characteristics of performance, which

in the case of actual use do not always

apply as described or which may change

as a result of further development of the

products. An obligation to provide the

respective characteristics shall exist only

if expressly agreed in the terms of contract.

Order No.: E20001-M6207-B100-X-7600

Printed in Germany

totally integrated

Flexibility will …

… grow

www.siemens.com/pharma

When productivity is clearly on the upyou have the formulae for success

Choose the right vaccines to keep your business fit and healthy.

Try productivity growth combined with validated solutions. Our

comprehensive automation technology is engineered to fit your

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