Project Insights

Advanced Tablet Bottle Filling & Capping Automation System

This project involves the design and implementation of a fully automated tablet bottle filling and capping machine developed for the pharmaceutical and packaging industry. The system is engineered to deliver high-speed, accurate, and reliable packaging operations while maintaining stringent quality and production standards.

The automation architecture is built around a Siemens S7-1200 PLC, which serves as the central controller for coordinating all machine operations. A Siemens Industrial PC (IPC) provides the operator interface, process monitoring, diagnostics, and production management functions.

For precise bottle positioning and indexing, a Siemens V90 Servo Drive is utilized, ensuring accurate movement and synchronization throughout the packaging cycle. Variable Frequency Drives (VFDs) control the conveyor, tube filling, and spinning motors, enabling smooth speed regulation and optimized machine performance.

The operational sequence begins with container indexing, where empty bottles are automatically positioned at the filling station. Tablets are then dispensed into each bottle with high accuracy, minimizing product wastage and ensuring consistent fill quantities. Following the filling process, bottles are transferred to the capping station, where caps are automatically picked, positioned, and securely placed onto the containers.

The system incorporates intelligent automation logic, safety interlocks, fault diagnostics, and real-time monitoring capabilities to maximize production efficiency and minimize downtime. The solution delivers enhanced productivity, repeatability, and operational reliability, making it an ideal packaging automation system for modern pharmaceutical manufacturing facilities.

Key Technologies:
• Siemens S7-1200 PLC
• Siemens Industrial PC (IPC)
• Siemens V90 Servo Drive for Bottle Indexing
• Variable Frequency Drives (VFDs)
• Automated Tablet Filling Mechanism
• Automatic Cap Placement System
• Real-Time Monitoring & Diagnostics
• Industrial Packaging Automation

PW & WFI Water Generation, Distribution and Recirculation System

The Purified Water (PW) and Water for Injection (WFI) Generation, Distribution, and Recirculation System is a critical utility solution designed for pharmaceutical manufacturing facilities where water quality directly impacts product safety, regulatory compliance, and process efficiency.

This project was developed to ensure the continuous generation, storage, distribution, and recirculation of pharmaceutical-grade water while maintaining stringent quality standards throughout the entire process. The system delivers Purified Water (PW) and Water for Injection (WFI) to multiple user points across the manufacturing plant, ensuring that water remains within specified quality parameters at all times.

The automation solution continuously monitors and controls critical process variables such as flow rate, pressure, temperature, conductivity, Total Organic Carbon (TOC), and pH levels. Through intelligent recirculation logic, the system prevents water stagnation and microbial growth, helping maintain water quality and compliance with pharmaceutical industry standards including GMP and regulatory guidelines.

The distribution network is designed to provide a consistent and reliable supply of purified water to production equipment, clean rooms, processing lines, CIP/SIP systems, and other critical utility points. Advanced monitoring and control systems ensure real-time visibility of the entire water treatment and distribution process, allowing operators to quickly identify deviations and take corrective actions.

The solution incorporates PLC-based automation, SCADA visualization, alarm management, data logging, and historical trending to provide complete process transparency and traceability. Operators can monitor system performance, review operational data, and generate reports for validation and compliance purposes.

By implementing this automated PW & WFI system, the pharmaceutical facility benefits from enhanced water quality assurance, reduced manual intervention, improved operational reliability, regulatory compliance, and optimized utility management.

Project Benefits

• Maintains Pharmaceutical Water Quality Standards
• Ensures Consistent Supply to Production Areas
• Reduces Risk of Contamination and Water Stagnation
• Improves Process Efficiency and Reliability
• Supports Regulatory Compliance and Validation Requirements
• Enables Centralized Monitoring and Control

Autoclave Sterilization System Automation

The Autoclave Sterilization System is a fully automated batch-processing solution designed to perform reliable and validated sterilization of pharmaceutical products, food-grade materials, laboratory instruments, and hospital equipment. The system plays a critical role in ensuring product safety, maintaining hygiene standards, and meeting stringent regulatory requirements across pharmaceutical, healthcare, biotechnology, and food processing industries.

This project involved the automation and control of an advanced autoclave system capable of executing multiple sterilization and cleaning cycles with high precision and repeatability. The system utilizes controlled temperature, pressure, steam, and time parameters to eliminate microorganisms, bacteria, viruses, and other contaminants, ensuring complete sterilization of materials and equipment.

The automation architecture continuously monitors critical process parameters including chamber temperature, steam pressure, vacuum levels, cycle duration, and sterilization hold times. Through intelligent batch management and recipe-based operation, the system allows operators to select predefined sterilization programs based on the specific product or equipment being processed.

The autoclave performs a series of automated process stages including pre-conditioning, air removal, vacuum generation, steam sterilization, holding, drying, cooling, and post-cycle verification. Additionally, specialized cleaning and sanitation cycles are incorporated to maintain chamber cleanliness and ensure consistent operational performance between batches.

The solution integrates PLC-based control, SCADA visualization, alarm management, data logging, and batch reporting to provide complete process traceability and validation support. Operators can monitor real-time process conditions, review historical trends, generate audit-ready reports, and manage recipes through an intuitive operator interface.

Designed in compliance with pharmaceutical and healthcare industry standards, the system supports GMP requirements, process validation, and regulatory documentation, ensuring safe and repeatable sterilization operations.

Key Features

• Fully Automated Sterilization Cycle Management
• Batch-Based Recipe Control System
• Steam, Temperature, Pressure & Vacuum Monitoring
• Automatic Cleaning and Sanitation Cycles
• Chamber Drying and Cooling Control
• Real-Time Process Visualization
• Alarm and Event Management
• Electronic Batch Recording and Reporting
• Historical Data Logging and Trending
• GMP-Compliant Automation Architecture

LPG & Ammonia Storage, Transfer and Liquid Filling Automation System

The LPG (Liquefied Petroleum Gas) and Ammonia Storage, Transfer, and Liquid Filling Automation System is a comprehensive industrial automation solution designed to safely manage the unloading, storage, monitoring, transfer, and loading operations of liquefied gases. The system is engineered to handle high-volume bulk storage and distribution processes while ensuring operational safety, process reliability, and regulatory compliance.

This project automates the complete material handling workflow, beginning with the unloading of Liquid LPG and Ammonia from marine vessels at the jetty. The product is transferred through dedicated pipeline networks into large-capacity storage tanks equipped with advanced instrumentation and safety systems. Once stored, the product can be distributed to downstream processing plants, bottling facilities, tanker loading stations, or transportation vehicles through a controlled and monitored transfer process.

The automation system continuously supervises critical process parameters including tank levels, pressure, temperature, flow rates, valve positions, pump status, and product inventory. Intelligent control logic ensures safe transfer operations while preventing overfilling, excessive pressure buildup, product loss, and hazardous operating conditions.

For liquid filling and dispatch operations, the system provides accurate flow control, batch monitoring, quantity measurement, and loading management to ensure precise product delivery. Automated interlocks and safety sequences help maintain safe operating conditions during tanker loading and unloading activities.

The solution integrates PLC-based control, SCADA monitoring, data acquisition, alarm management, and reporting systems to provide operators with real-time visibility of the entire terminal operation. Centralized monitoring allows efficient management of storage facilities, loading bays, transfer pumps, and utility systems from a single control platform.

The project is designed with a strong focus on safety and reliability, incorporating emergency shutdown (ESD) systems, high-level protection, leak detection integration, safety interlocks, and equipment protection mechanisms to safeguard personnel, assets, and the environment.

Key Features

• Ship-to-Storage Tank Unloading Automation
• LPG and Ammonia Transfer Management
• Automated Tank Farm Monitoring System
• Liquid Filling and Tanker Loading Control
• Real-Time Level, Pressure and Temperature Monitoring
• Flow Measurement and Inventory Management
• Automated Valve and Pump Sequencing
• Safety Interlock and Emergency Shutdown (ESD) Integration
• Alarm Management and Event Recording
• SCADA-Based Centralized Monitoring and Control

Have a Similar Automation Requirement?

Discover how GatiLek transforms complex industrial challenges into intelligent, reliable, and future-ready automation solutions.