Digital processes for natural medicine production

Die Human-Machine-Interfaces (HMI) von Systec & Solutions sind die Schnittstelle in der digitalisierten Reinraum-Produktion. (Bildnachweis: @pascoe naturmedizin) / The human-machine interfaces (HMI) from Systec & Solutions are the interface in digitalized cleanroom production. (Picture credits: @pascoe naturmedizin)

Pascoe Naturmedizin legt nicht nur viel Wert auf standardisierte Prozesse in der Produktion seiner Rohstoffe, sondern auch auf ein schönes Design der dafür genutzten Technik. (Bildnachweis: @pascoe naturmedizin) / Pascoe Naturmedizin not only places great emphasis on standardized processes in the production of its raw materials, but also on a nice design of the technology used. (Picture credits: @pascoe naturmedizin)

Die GMP-konformen Panels von Systec & Solutions zeigen den aktuellen Status jedes Produktionsraums: intelligent, energieeffizient und netzwerkfähig. (Bildnachweis: @pascoe naturmedizin) / The GMP-compliant panels from Systec & Solutions show the current status of every production space: intelligent, energy-efficient and with network capability. (Picture credits: @pascoe naturmedizin)

Modern natural medicine begins with the manufacturing process. Pascoe pharmazeutische Präparate GmbH from Gießen develops and produces medications, food supplements and high-dose vitamin preparations, which are exported to more than 30 countries. The high-quality, mainly locally grown raw materials are processed using a standardized, digital process. Production manager Dr Rudolf Unger relies on HMI solutions from Systec & Solutions, which allow working in a cleanroom up to Class A.

Harvested by hand. For over 125 years, Pascoe Naturmedizin has relied on an exceptionally careful exploitation of its raw materials for production of active ingredients. As soon as the healing plants have been approved by the critical eyes of the botanists and pharmaceuticals experts, they enter a standardized production process with defined flow traces that comply with stringent GMP guidelines. For example, this guarantees that every tablet contains the same amount of the correct active ingredient.

“At the end of the 2000s, we began to control and document our production processes paperlessly using SAP”, says Dr Rudolf Unger. As Production Manager at Pascoe, he appreciates the benefits of this early digitalization. “We have one hundred percent traceability with reliable documentation and archiving thanks to the change management service. And thanks to immediate posting our stock situation is always right up to date.”

For production of active ingredients in a cleanroom, Unger depends on the Life Science ready solutions from Systec & Solutions in Karlsruhe. “After a joint inspection of the building site with the project manager from Systec & Solutions, they worked with us to define the requirements for each individual workstation. Because of this planning, the permanently installed HMI systems in all production areas are now installed in such a way that they are perfectly integrated into the overall process. For example, on a work platform at a height of around three meters, or directly adjacent to the controls for larger systems.”

Direct access to the HMI systems is essential to promote digitalization in all areas. Cleanroom technology plays a crucial role as an interface between people and the machines. As all work steps are posted immediately, not only is the process transparent and controllable, a lot of paper is saved. This is a factor that fits right in with the company’s sustainability philosophy and allowed a rapid switch to mobile working in 2020.

Transparency plays a major role, not only in the cleanroom itself, but also for controlled access. Intelligent panels from Systec & Solutions have also been installed in the wall at the entrances to every production area. They indicate whether the room is currently being used and, if so, for which product and which batch, whether it has been cleaned and is ready for operation or whether it is currently in quarantine mode.

In addition to the high technical functionality, the design was also a key reason behind Pascoe choosing products from the Karlsruhe based company. The planning and construction of the new building in 2020 focused not just on optimizing processes but also on a design based on Feng Shui principles. Employees should feel comfortable and a “glass production facility” should give visitors a glimpse of production. “The lean and visually appealing solutions from Systec & Solutions were the best choice for us from a design perspective,” says Unger.

Pascoe also took advantage of the manufacturer's installation and qualification service. “The supplier knows their products better than anyone”, says Production Manager Unger, speaking from personal experience. “As a manufacturer of medicines, system qualification in line with GMP guidelines is mandatory for us. By having Systec & Solutions carry out the installation and the functional qualification, we were able to achieve an optimum, functional and fast result.”