Process Automation
Process automation is central to how we help our clients increase efficiency, ensure compliance, and future-proof their operations. At KeyPlants Automation, we provide end-to-end automation solutions – from feasibility and design to implementation, testing, and commissioning. With over 50 specialized engineers and decades of experience, we deliver robust, compliant systems tailored to your needs. We work across platforms and suppliers, ensuring seamless integration with your operations – no matter the complexity.
Distributed Control Systems (DCS)
PLC/SCADA Solutions
At KeyPlants Automation, we specialize in designing and implementing Distributed Control Systems (DCS) tailored to the unique needs of industries like pharmaceuticals, oil & gas, and discrete manufacturing. Our expertise spans leading platforms such as Siemens PCS7, Siemens PCS Neo, ABB Sattline, and Emerson DeltaV, ensuring seamless process control and optimization.
End-to-End Solutions:
From conceptual design to commissioning, we deliver fully integrated DCS solutions, including software and hardware, that align with your operational goals and investments.
Regulatory Compliance:
Our systems are designed to meet stringent regulatory standards, including GMP and GxP, ensuring compliance in highly regulated industries.
Scalability:
Whether you need a small-scale system or a plant-wide DCS integrated with MES/ERP platforms, we provide scalable solutions that can grow with your business.
Digital Twin Technology:
Leverage our expertise in Siemens gProms and SIMIT for advanced process modeling and digital twin development, enabling predictive maintenance and process optimization.
We have extensive experience with PLC/SCADA solutions, and we offer system-independent designs and configurations, ensuring compatibility with your existing infrastructure.
Customized Solutions:
From simple standalone systems to complex, multi-site integrations, we deliver PLC/SCADA solutions that meet your specific requirements.
Remote Monitoring:
Our systems can enable remote access for real-time monitoring, troubleshooting, and control, reducing downtime and improving response times.
Integration Expertise:
We can design your PLC/SCADA system to integrate with DCS, MES, and ERP platforms for a unified operational environment.
Proven Track Record:
With experience in industries ranging from pharmaceuticals to biofuels, we have a proven track record of delivering highly reliable and efficient automation solutions.
At KeyPlants Automation, we specialize in designing and implementing Distributed Control Systems (DCS) tailored to the unique needs of industries like pharmaceuticals, oil & gas, and discrete manufacturing. Our expertise spans leading platforms such as Siemens PCS7, Siemens PCS Neo, ABB Sattline, and Emerson DeltaV, ensuring seamless process control and optimization.
End-to-End Solutions:
From conceptual design to commissioning, we deliver fully integrated DCS solutions, including software and hardware, that align with your operational goals and investments.
Regulatory Compliance:
Our systems are designed to meet stringent regulatory standards, including GMP and GxP, ensuring compliance in highly regulated industries.
Scalability:
Whether you need a small-scale system or a plant-wide DCS integrated with MES/ERP platforms, we provide scalable solutions that can grow with your business.
Digital Twin Technology:
Leverage our expertise in Siemens gProms and SIMIT for advanced process modeling and digital twin development, enabling predictive maintenance and process optimization.
We have extensive experience with PLC/SCADA solutions, and we offer system-independent designs and configurations, ensuring compatibility with your existing infrastructure.
Customized Solutions:
From simple standalone systems to complex, multi-site integrations, we deliver PLC/SCADA solutions that meet your specific requirements.
Remote Monitoring:
Our systems can enable remote access for real-time monitoring, troubleshooting, and control, reducing downtime and improving response times.
Integration Expertise:
We can design your PLC/SCADA system to integrate with DCS, MES, and ERP platforms for a unified operational environment.
Proven Track Record:
With experience in industries ranging from pharmaceuticals to biofuels, we have a proven track record of delivering highly reliable and efficient automation solutions.
FAQ
FAQ
How does modern automation with digital integration transform pharmaceutical manufacturing?
Today’s advanced automation goes beyond basic control—it’s a compliance and efficiency multiplier. Our solutions replace paper-based workflows with digital batch records, enable real-time deviation management, and embed ALCOA+ data integrity principles directly into processes. The result? Faster release cycles, reduced human error, and audit-ready operations 24/7.
How does KeyPlants guarantee compliance and quality in automation projects?
We deploy our own Quality-by-Design Framework, developed with industry compliance experts and tested across many GMP projects. Every phase—from design and FAT to SAT and qualification—follows validated protocols with built-in traceability. Our approach combines:
- Pre-emptive risk control: Hazard analysis integrated into automation design
- Zero-gap validation: Documentation aligned with EU Annex 11/21 CFR Part 11
- Lifecycle ownership: Post-handover support for continuous compliance
How do you implement automation upgrades without disrupting production?
Our proven methodology combines rigorous testing with careful planning:
We begin with risk assessments at every project phase, followed by virtual commissioning using digital twin technology. All hardware undergoes FAT testing in our workshop, while system functionality is verified through hardware-in-the-loop simulations. Before full implementation, we conduct parallel runs with existing equipment during planned maintenance windows, accompanied by comprehensive operator training.
What industries does KeyPlants Automation serve?
Our industrial process automation solutions are tailored for pharmaceutical, biotech, life sciences, and other regulated industries that require high precision, compliance, and efficiency in manufacturing operations.
Our rigorous project execution delivers value to any project needing:
- Regulation-ready systems: Food/beverage, cosmetics, or chemical clients benefit from our compliance expertise
- Mission-critical reliability: Data center or energy projects leverage our fault-tolerant designs
- Fast-track deployments: Startups scale faster with our modular automation templates
What makes KeyPlants’ automation approach unique?
Our vendor-agnostic agility means we select—not sell—the optimal technology for your goals. By combining:
✔ Platform neutrality: No locked-in proprietary systems
✔ Collaborative implementation: We work alongside your technical teams, combining process knowledge with automation expertise
✔ Outcome-based design: Automation that solves business problems, not just technical ones
…we deliver solutions that remain adaptable to future needs.
Next-Gen Process Control
KeyPlants Automation delivered the Nordic region's first Siemens PCS Neo implementation, establishing a new standard for modular process automation. The web-based control system seamlessly integrated OEM equipment using Module Type Package (MTP) technology, reducing commissioning time by 60% compared to traditional methods.
The solution connected process units through standardized MTP interfaces in Siemens TIA Portal while maintaining full batch execution capabilities. This future-proof architecture enables ongoing expansion with plug-and-play module integration, from utility systems to full production lines, all while ensuring native MES connectivity for complete vertical integration.
Biotech Capacity Expansion
We successfully expanded a biotech facility's production capacity by integrating eight new units into an existing DeltaV batch system. The upgrade incorporated 1,500 I/O points while maintaining continuous operations through careful phased implementation and Profibus/Foundation Fieldbus integration.
The enhanced system achieved seamless data exchange with site-wide BMS, EMS and MES platforms. By preserving the existing automation architecture while adding scalable capacity, we delivered a 30% production increase without compromising the facility's validated state or requiring complete system replacement.
Process Automation That Delivers Measurable Results
Process Automation That Delivers Measurable Results
We design, implement, and optimize automation systems for pharmaceutical and industrial manufacturers who need to:
- Boost productivity without compromising quality
- Simplify compliance with built-in GMP/GxP functionality
- Future-proof operations through scalable architectures
Our vendor-agnostic approach combines proven methodologies with cutting-edge technology—from advanced process control to seamless MES integration—ensuring systems that perform today and adapt tomorrow.
Let’s build your competitive advantage.
