Programmable Logic Controller (PLC) Calibration

Programmable logic controllers (PLCs), play an important role in the control and automation of various manufacturing processes in biopharmaceutical industries to maintain the precision and accuracy of the manufacturing process for ssafety and product quality. As an ISO 17025 certified company, we provide equipment calibration and certification services for biopharmaceutical organizations throughout California. We not only maintain our clients laboratory and manufacturing equipment for accuracy and reliability, we also keep our clients compliant with industry standards to meet regulation requirements.

To speak with the experts about your PLC calibration needs, please fill out our online form or give us a call!

858-202-1408

What is a Programmable Logic Controller?

A programmable logic controller (PLC) system in the biopharmaceutical industry refers to a specialized control system used to automate and monitor various processes involved in the manufacturing of pharmaceuticals. PLCs are computer-based devices that are capable of receiving input signals, process them, and generate output commands to control machinery and equipment. Biopharmaceutical companies employee PLC systems to manage critical operations such as fermentation, purification, and sterilization. They facilitate control over temperature pressure, pH levels, agitation rates, and other necessary variables for the best performance and functionality of bioreactors, centrifuges, and filtration systems. The system provides accuracy, reliability, and repeatability which play the largest role in maintaining product quality and meeting regulatory requirements.

Importance of PLC Calibration in Manufacturing

Quality Assurance

Accurate calibration of PLCs is important for maintaining product quality and consistency. In the biopharma manufacturing industry, it involves exact control of critical parameters including temperature, pressure, and flow rates. A mis-calibration in the PLC can lead to variations in these parameters which can compromise the quality of the final product. Regular calibration makes sure that PLCs are operating as required and reduces the risk of product deviations.

Compliance with Regulatory Standards

As biopharmaceutical companies are well aware, they are highly regulated and need to stick to strict quality and compliance standards. Calibration is an important aspects of regulatory compliance. The FDA and the cGMP emphasize the importance of calibration so the equipment in the manufacturing process provides reliable and accurate measurements. A properly calibrated PLC helps organizations meet regulatory requirements and facilitate smooth inspections.

Best Practices for PLC Calibration

Calibration Schedule

Establishing a calibratino schedule is important fo rmaintaining the accuracy and reliability of programmable logic controllers (PLCs). A robust schedule verifies that the PLCs are meeting performance standadrs and regulation requirements. To develop an effective calibration schedule, there are a few best practices that should be following. Start by identifying critical PLC components and their calibration intervals based on the manufacturer's recommendations. Next, document all calibration activities including the dates, results, and technician or company information to keep a record of history. Incorporate predictive techniques such as condition monitoring and trending data analysis to improve calibration intervals.

Documentation

Best practices for PLC calibration documentation includes record keeping of all calibration procedures, dates, and results. Each calibration should be thorougly documented, including details including the instrument used, the technician or company that performed the calibration, and any adjustments that were made. It's important to maintain a centralized database to track calibration history and provide a reference for future troubleshooting and audits. Documentation needs to adhere to industry guidelines with clear and concise descriptions of the calibration process.

Calibration Standards and Equipment

It's important to follow recognized standards such as ISO 9001 and ANSI/ISA-75.01.01 to maintain both consistency and quality throughout the calibration process. Next, establishing a comprehensive calibration schedule based on manufacturing guidelines and industry recommendations for regular calibration checks. It includes setting up a robust system for tracking and documenting calibration activities. With the utilization of traceable references and calibrated test equipment guarantees the accuracy of the results.

Change Control

It's also important to establish a comprehensive change control policy that outlines the procedures for any modifications or updates to PLC configurations. The policy should include clear documentation that details the changes made, the reasons why, and the individual or consultant responsible. A thorough review and approval process should be in place to evaluate the impact of proposed changes on PLC calibration for compliance with regulatory requirements. Regular training sessions should be conducted to educate personnel about the importance of change control and to keep employees informaed about any updates or modifications.

Why GL-Tec?

The GL Technologies team has the experience and equipment to calibrate all types of display equipment accurately. We understand the importance of accurate measurements in your specific industry, and we're committed to providing you with reliable, traceable calibration services.

Our calibration services are ISO 17025 accredited, and we follow strict quality control procedures. Your equipment is calibrated to the highest standards. We also provide fast turnaround times, so you can get back to work with minimal downtime.