Optimizing Pharma Packaging Lines with PLC-Based Automation

Each control function (label check, temperature control, and serialization) is isolated, documented, and tested. Makes mapping to URS and FS clean.

FAT, SAT, IQ, and OQ scripts get tied to the logic itself. No need to retrofit test coverage later.

Whether it’s an HMI input or parameter change, your PLC logs who did what. Timestamps included. That’s your audit trail, built in.

Need to show that the sealing temperature wasn’t altered mid-batch? Or that label rejections followed SOP? The logs sit right there in the controller, formatted and searchable.

So instead of building compliance around automation, you design it into the system from the very start.

They won’t just understand PLCs, they’ll know GAMP 5, cleanroom constraints, serialization mandates, and how MES talks to packaging.

No need to rebuild a print-inspection routine from scratch. The right partner brings tested blocks ready to validate again.

Your Line 1 runs on Siemens, Line 2 on Rockwell, and you’re testing Beckhoff next year? Great. They should be fluent in all three.

You want to integrate sensors, push data to the cloud, or plug into an MES? The partner builds your PLC system ready for those connections, without needing a full rip-and-replace later.

That’s the role we play at Azilen, coming in as that embedded software partner who knows your industry inside out, and builds PLC automation solutions for pharma packaging that scale, pass audits, and keep lines running smart.

By embedding logic that responds in real time (adjusting speeds, correcting faults, and managing changeovers), PLC automation helps reduce downtime, increase throughput, and maintain quality.

That directly lifts OEE from sub-40% to the 65–85% range when done right.

It’s the layer that connects physical control (PLCs, actuators, sensors) to business rules and compliance.

Think of it as the smart brain that ensures your line not only runs but runs right – batch-aware, GAMP-compliant, and fully traceable.

Yes. Most upgrades are logical, not mechanical. We retrofit embedded PLC software into your current setup, giving you modern control, data visibility, and compliance without replacing the line hardware.

It simplifies it. Modular logic tied to functional specs, automated logging, role-based access, and test-ready designs reduces manual documentation while aligning perfectly with GAMP 5 expectations.

Traditional automation runs the line. Embedded logic makes the line smart. It manages context (batch size, packaging type, operator actions, etc.) and acts accordingly, with full traceability and QA integration.

1️⃣ PLC (Programmable Logic Controller): An industrial digital computer used to control manufacturing processes, including real-time packaging line equipment like feeders, sealers, and rejection systems.

2️⃣ Embedded Software: Code that runs on dedicated hardware like PLCs or microcontrollers to control specific functions of a device or machine.

3️⃣ OEE (Overall Equipment Effectiveness): A measure of production line performance that combines availability, performance, and quality.

4️⃣ GAMP 5: A risk-based approach to compliant GxP computerized systems, widely used in pharma automation to ensure system quality and documentation standards.

5️⃣ 21 CFR Part 11: A U.S. FDA regulation that establishes criteria for electronic records and electronic signatures to ensure data integrity in regulated environments.