Everything’s ready for the pharmaceuticals sector
Interview: Turck offers a wide range of solutions to the pharmaceuticals industry

The pharmaceuticals sector is attracting increasing attention from process automation providers. In the PROCESS interview, David Fazzini, global director for the pharmaceuticals industry at Turck, gives an overview of the level of automation in the sector and reveals the specific products that Turck has in its portfolio.
? Mr. Fazzini, Turck booked two-digit growth rates in the last years. What role does the pharmaceuticals industry play in your growth strategy for process automation?

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? What are your goals for the next few years?

Fazzini: Our goals and objectives to continue growth in the pharmaceutical industry for the next few years will be to continue to support the industry in key, and emerging geographic areas with the basic strategy of offering product and technology innovations to support the needs of the customer based on the particular requirements of the project i.e. a compressed time to market scenario for construction, cost reduction or implementation of advanced digital process control systems. Secondly, the organization will continue to provide the end user, engineering firm and construction manager the necessary project management services from basis of design through start up and commissioning. This process can be executed on a global basis with transparency and accountability.

?  What characteristics are particular to the pharmaceuticals sector and how does Turck take account of these characteristics?

Fazzini: We are seeing more and more outsourcing of engineering and modular construction and concurrently end users are specifying advanced digital control systems for new construction projects. As a result more reliance is placed on the suppliers to properly guide engineering through detailed design with the proper configuration of hardware to suit the control strategy and coordination with module constructors to develop and execute best practices for hardware implementation. Turck is uniquely positioned to support this process.

? Business in the pharmaceuticals industry is largely project-driven. Which strategies and forms of organization are you using to meet these demands?

Fazzini: Coordination and communication on a global basis is a must to successfully execute a pharmaceutical project. It is quite conceivable that an end user could be based in Europe, the detailed specification could be created in the USA, equipment could be supplied from several global suppliers and the job site could be in Ireland or Singapore. Finally, the site will be fitted out and commissioned by a local contractor, all in compliance with local codes and practices. In this scenario there can be no barriers to disrupt the process and information must flow freely, accurately and quickly. These dynamics demand a global, flexible, highly technical project team that can execute the project from conception to final commissioning.

? In which production areas of the pharmaceuticals industry can Turck products be used?

Fazzini: Turck technology can be implemented from the DCS cabinet to the final control element at the reactor, fermentation suite, formulation and fill/finish lines.

? Which of your products can be used in these areas?

Fazzini: Starting in the DCS cabinet, when implementing a digital network such as Foundation Fieldbus or Profibus PA we offer Diagnostic Power Conditioning systems for general purpose or FISCO applications. For quick change out of sanitary seals or change out of instrumentation we offer a full line of connectorization for sensors and actuators in the process areas. We offer different sensing technologies for flow and level detection, sensing of rotational valve position and transfer panels. For the interface of traditional signals to a digital network Turck offers a complete line of remote I/O products that have the option of being mounted either inside or outside the control cabinet. Additionally for hazardous locations we offer intrinsically safe remote I/O as well as individual isolation barrier. One of our newer products that is gaining a lot of attention in the pharmaceutical industry is our BL Ident Radio Frequency Identification system, which could serve in a number of the applications in the pharmaceutical process.

? Where are Turck products already being used successfully in the pharmaceuticals industry?

Fazzini: Level and flow detection, rotational valve and transfer panel position sensing, IS barriers and IS Remote I/O for hazardous area locations, standard Remote I/O for general purpose areas. Cordsets and connectors for sensors and actuators. Turck also supports a full range of products for implementation of advanced digital networks such as Profibus DP/PA, FF, ASI, Devicenet, and Ethernet, implemented in either general purpose or hazardous areas.

? What opportunities are opened by the FDA’s PAT initiative specifically for Turck as a process automation provider and sensor manufacturer?

Fazzini: The goal of PAT is to better control and understand the manufacturing processes with the goal of continuous quality monitoring and improvement. One of the keys to this is of course automation, when you automate the process you get better information and more knowledge. With many of the above mentioned products from Turck, we deliver leading diagnostics and configuration documentation tools which play right into the goals of PAT. When you automate the process with Turck you get the tools to incorporate the diagnostics and configuration management into the operation and maintenance strategy of the plant.

? Insiders complain that the level of automation in the pharmaceuticals industry is still inadequate. How do you see the situation and where do you see a concrete backlog?

Fazzini: Typically, mature, existing facilities are wired to traditional DCS systems. These systems are validated and will not be changed or substantially modified. However, when the end user takes the initiative to migrate to a newer DCS or PLC technology the opportunity exists for implementation of advanced digital control networks, systems and components. This opens the door to take advantage and implement new technologies and innovations. For new construction, obviously this is the best opportunity to implement advanced automation technologies, and this is where we see our greatest activity.

? The pharmaceuticals market is largely USA-driven. What are the regional points of emphasis at Turck? Where do you see important growth markets?

Fazzini: The majority of the large pharmaceutical end users and A&E firms tend to be located on the East and West Coasts of the USA. This is a result of the availability of large pools of investment capital and institutions of higher learning and research firms heavily involved in R&D. In addition to the current strongholds of pharmaceutical production, Ireland, Puerto Rico, Singapore, USA, we see the important future growth markets in the Asia Pacific Region, Eastern Europe, and countries with developing economies.

? How does the American market differ from the European market?

Fazzini: I believe this is a macroeconomic concept driven largely by the level of government involvement in the pharmaceutical industry. Companies in the USA are less exposed to environmental impact liability, benefit from lower tax burden, have greater patent protection to protect R&D investments, and on balance are not subject to price controls for the sale of drugs. In the aggregate this allows the industry to thrive financially which drives further R&D and promotes growth and innovation.

? The share of biopharmaceutical ingredients continues to grow. Which of your systems are suitable for use in fermenters/bioreactors? Are you planning new developments for such applications?

Fazzini: Our core products for the production area as outlined above level, flow, position sensing; Interface for Hazardous and general purpose areas; a complete line of Remote I/O and cordsets and connectors for sensors and actuators. Turck also supports a full range of products for implementation of advanced digital networks such as Profibus DP/PA, FF, ASI, Devicenet, and Ethernet. This core line is continually modified or expanded to meet the specific needs of the customer.

? In your opinion, which important trends will dominate pharmaceuticals production in the new few years?

Fazzini: The key trends we are seeing are implementation of advanced control systems such as FF or Profibus PA, implementation of advanced diagnostics, outsourcing of engineering and skidded or modular construction. All these trends are driven by the need for cost competitiveness, the availability of fewer trained plant operators and the need to bring products to market quickly to produce optimal revenue streams before patent expiration. From a supplier’s perspective the relationship has transitioned into trusted partnerships with long term commitments to ensure that the end user is successful in his efforts to bring products to market in a profitable fashion.