Modernizing Control Systems for a Smarter, More Connected Facility
By consolidating servers, upgrading automation platforms, and deploying a VMware infrastructure, the team delivered end-to-end visibility, reduced licensing costs, and unified IT/OT operations—driving efficiency and long-term value.
Challenge:
One of the top ten pharmaceutical companies embarked on a mission to modernize its control systems, which were fragmented across multiple standalone servers and visualizations. This setup hindered coordination and data exchange between automation islands, limiting operational efficiency and scalability.
Solution:
E Tech Group delivered a robust modernization strategy that included upgrades to DeltaV, Rockwell PLC, EBmR networks, and peripheral systems. All automation applications, including batch and continuous historians, were migrated to newer validated versions. A VMware infrastructure was designed to host DeltaV systems and OSIsoft PI interfaces, ensuring future scalability.
Results:
The implementation resulted in a next-generation system with end-to-end visibility of plant operations. IT and OT convergence was achieved, and multiple servers were consolidated into a single redundant infrastructure. Field technicians and operators gained seamless access to monitor equipment, and licensing costs were reduced by 17% annually. The project exemplified how strategic upgrades can drive operational excellence and cost savings.
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