Modular MES System Controls €50m Czech Lonza Biotec Plant

Lonza Biotec s.r.o. in the Czech Republic, one of the world‘s leading suppliers to the pharmaceutical, healthcare and life science industries, has invested in a multi-product manufacturing facility that increases the company’s fermentation capacities by 50%. The combined Production Management and Weighing System, for this facility is controlled by a web-based PILOT® MES/WDS from FELTEN in Germany. FELTEN designed and implemented the entire Lonza system in just 6-months, using cost effective PILOT software modules that combine hardware from different suppliers into one homogeneous system. The system’s numerous interfaces and modular structure mean that it is fully open for future expansion, and has the potential for SAP connection in the near future.
Lonza has more than 6400 employees worldwide and owns 23 production and R&D sites, including Lonza Biotec s.r.o. in the Czech Republic, which was founded in 1992., Lonza Biotec s.r.o employs more than 350 people and specialises in the production of API intermediates and L-carnitin.
Lonza’s investment in the new multi-product manufacturing facility was necessary to meet the increasing demands for microbiological products for pharmaceutical applications, and also human nutrition supplements. Key to the success of the overall project was Lonza’s requirement for a combined Production Management and Weighing System. When selecting the system platform, Lonza attached great importance to efficiency, scalability and the widest range of system capabilities. In addition the company wanted a system that would provide transparent process workflows and optimised processes to enable the maximum in cost saving, delivering a quick return on investment (ROI).
FELTEN GmbH from Serrig, Germany was able to satisfy all of Lonza’s requirements with its web-based PILOT® [MES] Weighing and Dispensing System, and was awarded the order for the combined system.
The web-based FELTEN system convinced Lonza with a number of key features. First, with its upgradeability: the result of the modular structure of PILOT MES. Second, the ability for complete integration into the existing automation and system structure. Third, the system’s easy, quick and safe operability. Fourth, the PILOT system’s strict compliance with FDA and cGMP regulations.
The PILOT® MES Production Management System provides an integrated solution that connects business order processing from ERP systems with automation control systems. It provides a cost effective solution that meets all requirements; and reveals weak points as well as bottlenecks in production processes. As the software is implemented as a web portal, any business- relevant data and processes are made available company-wide. The operation is intuitively carried out, using a standard web browser with mobile clients (PDAs), which are connected to the PILOT® system via wireless LAN.