The challenge
What needed to change.
The existing controls were approaching end of life and no longer met current safety expectations. The proven process still had to be reproduced consistently.
Control systems · Life sciences & chemical
Ball-mill control system upgrade
A modern control and safety platform that preserves a validated process while improving flexibility and traceability.
ClientThermo Fisher ScientificSectorLife sciences & chemicalPrimary disciplineControl systems
Adbro’s approach
How the solution was engineered.
Adbro delivered mechanical safety improvements, new electrical controls, process programming and operator interfaces as one GAMP-aware upgrade.
The outcome
What the project delivered.
The plant now has a safer, more supportable and traceable process, with a clear platform for future automation improvements.
Technical delivery
Inside the engineered solution.
The detail below shows how the main equipment, software and interfaces were brought together—not just what the project achieved.
System scope
- Siemens S7-1500 failsafe PLC and ET200SP I/O
- G120C drives over PROFINET and PROFIsafe
- Pilz emergency-stop and guard-locking devices
- Bespoke encoder coupling and position feedback
- Stainless-steel product-handling trolley with coded detection
- HMI with user management, audit trail and electronic signatures
- Mechanical guarding and cable-management upgrades
Validated-process replication
The control sequence and speed regulation were developed to reproduce the established process while moving it onto a supportable platform. Position and speed feedback were engineered around the existing machine constraints.
Bespoke mechanical interfaces
A split helical face gear, supported shaft and pinion arrangement provided an encoder interface where the original machine had no mounting provision. A stainless-steel trolley and coded actuator supported safe ball removal.
Integrated standard and safety control
The failsafe Siemens controller combines process and safety logic, with distributed ET200SP I/O reducing field wiring. G120C drives communicate over PROFINET with safety functions carried through PROFIsafe.
Traceable operation
The HMI manages process values, positioning, alarms, user access and data logging. Process-critical changes use electronic signatures, while manuals and electrical schematics remain available at the machine.
Verification & handover
The upgrade was delivered within a GAMP-aware project structure. Testing demonstrated repeatable execution of the established process, safe access after rundown, trolley and outlet monitoring, emergency-stop behaviour, user permissions, alarm history and traceable parameter changes.
Project highlights
PLC migrationProcess controlSafety upgradeTraceability
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