Upgrading control systems in a contract development and manufacturing (CDMO) environment requires careful planning to minimise downtime. Our client needed to upgrade the control system for a spray dryer to meet UKCA requirements while keeping costs low and production disruptions minimal. By working with ILS Group, they achieved an efficient off-site upgrade using pre-used equipment, delivering a cost-effective solution without unnecessary delays.
Project
Our CDMO client required a control system upgrade for their spray dryer to comply with UKCA certification. Given the high-paced nature of their operations, downtime had to be kept to an absolute minimum. The challenge was finding a way to implement the upgrade efficiently without causing unnecessary disruption or escalating costs.
To achieve this, ILS Group developed a strategy that allowed the control system to be upgraded off-site. By removing the existing system, carrying out the upgrade remotely, and then reinstalling it with precision, we minimised disruption to the client’s operations. Using pre-used equipment further reduced costs while maintaining the required functionality and compliance.
Challenges and Solutions
- Minimising Downtime: The client needed a solution that wouldn’t interrupt production for long. Our off-site upgrade approach ensured installation and re-integration happened quickly and smoothly.
- Regulatory Compliance: Meeting UKCA standards was a key objective. Our team ensured that all necessary certifications and requirements were met before reinstallation.
- Cost Control: By incorporating pre-used equipment, we provided a high-quality solution at a reduced cost without compromising performance.
Results and Client Impact
- Minimal Disruption: The project was completed with almost no downtime, allowing the client to maintain production schedules.
- Significant Cost Savings: The use of pre-used equipment reduced overall project costs while delivering a fully compliant system.
- A Satisfied Client: The engineering manager noted, “ILS Group delivered this upgrade in a challenging timeline, and we’re very happy with the results.”
Conclusion
This project demonstrated how strategic planning and execution can streamline complex system upgrades. By leveraging off-site work and cost-effective solutions, we ensured a smooth transition with minimal operational impact. The success of this upgrade strengthens our relationship with the client and highlights ILS Group’s ability to deliver tailored, efficient, and cost-conscious solutions in regulated industrial environments.
