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Future-ready automation, SCADA, PLC, and IoT integration to maximise production uptime, data visibility, and regulatory compliance across your entire pharmaceutical manufacturing operation.
GentlemanPharmed designs and commissions turnkey automation architectures for oral solid dosage, liquid filling, and sterile injectable production lines. By integrating servo-controlled kinematics, robotic pick-and-place systems, and intelligent sensor networks, we transform discrete machines into synchronized, continuous manufacturing lines. All automated sequences are structured according to GAMP 5 Category 4 and 5 software guidelines, featuring comprehensive fail-safe interlocks, electronic recipe management, and automated clean-in-place (CIP) cycling.
Recipe-Driven Batch Execution
Automated setpoint download for speed, temperatures, dosing volumes, and compression forces with strict recipe change authorization.
Deterministic Process Interlocks
Hardware and software safety interlocks that immediately halt upstream feeds if critical downstream parameters deviate.
Automated CIP / SIP Cycle Sequences
Pre-programmed validated wash sequences with flow, conductivity, and temperature logging for cleaning validation.
High-Speed Vision Inspection Synchronization
Millisecond-accurate trigger synchronization for line-scan cameras inspecting tablet surface defects and blister seal integrity.
Unlock the power of Industry 4.0 with GentlemanPharmed's Industrial IoT (IIoT) monitoring platform. By deploying non-invasive industrial edge gateways on new or existing pharmaceutical machinery, we continuously collect and analyze critical operating parameters including bearing vibration, motor winding temperature, vacuum pull, and pneumatic pressure. Our predictive algorithms identify mechanical wear, unbalance, and lubrication breakdown days or weeks before catastrophic equipment failure occurs, allowing maintenance teams to schedule interventions during planned downtime.
Plug-and-Play Edge Gateways
Non-invasive sensors connect directly to machinery without altering validated PLC control software.
Predictive Vibration & Temperature Analytics
Triaxial accelerometer sensors monitor ISO 10816 vibration severity on main drive bearings and turrets.
Mobile & Cloud Executive Dashboards
Secure real-time KPI dashboards showing live OEE, yield, and machine status on desktop and mobile devices.
Automated Maintenance Work Orders
Triggers proactive maintenance alerts via email/WhatsApp when parameter trends exceed baseline thresholds.
GentlemanPharmed's in-house electrical and automation engineering team designs, builds, and programs high-reliability PLC control systems for pharmaceutical machinery. Working with Siemens (S7-1200 / S7-1500 / TIA Portal), Rockwell Automation (ControlLogix / CompactLogix), and Mitsubishi Electric (MELSEC iQ-R / iQ-F), we deliver clean, modular, and fully documented control logic. Every control panel is fabricated in our Kolkata engineering workshop with strict separation of high-voltage power and 24VDC control circuits, full wire ferrule labeling, safety relays conforming to Category 4 / SIL 3, and thermal calculations for cleanroom deployment.
Multi-Platform PLC Expertise
Expert programming in Siemens TIA Portal, Rockwell Studio 5000, and Mitsubishi GX Works using structured text and ladder logic.
TÜV-Certified Safety Architectures
Integrated safety PLCs and safety relays for emergency stop circuits, guard door interlocks, and light curtains.
Modular Stainless Steel Panels (IP65)
Custom enclosures in AISI 304/316 stainless steel with vortex coolers or closed-loop air conditioners for cleanrooms.
Comprehensive I/O Wiring & Testing
100% point-to-point I/O loop testing and FAT simulation before dispatch to client sites.
Connect your entire production floor into a single, unified supervisory control and data acquisition (SCADA) platform. GentlemanPharmed provides custom SCADA solutions built on industry-standard platforms (Siemens WinCC, Wonderware / AVEVA, Rockwell FactoryTalk, Ignition), connecting tablet presses, fluid bed dryers, packaging lines, and cleanroom HVAC systems. Our SCADA systems deliver live KPI dashboards, long-term historical trending, and automated electronic batch records with 21 CFR Part 11 compliant audit trails, accessible securely by plant managers and quality assurance teams.
Real-Time Process Visualization
High-resolution mimic diagrams displaying live machine states, motor currents, pressures, temperatures, and fill levels.
Electronic Batch Records (EBR)
Automated generation of tamper-proof PDF batch reports upon batch completion, complete with time-stamped parameter logs.
Centralized Alarm & Event Logging
Hierarchical alarm classification with automated SMS/email notifications and mandatory operator acknowledgment comments.
OPC-UA & MES Interoperability
Open architecture connectivity supporting seamless bi-directional data exchange with ERP (SAP/Oracle) and MES platforms.
Our automation engineers will design a custom solution for your facility.