Marifarm, based in Maribor, has a fully integrated drug manufacturing process in place, which includes tablet production and packaging. While the majority of the company’s products are produced and packaged for other brands, Marifarm is also developing its own brands.
Area
Pharmaceutical Industry
Challenges
As a contract manufacturer for other pharmaceutical companies, Marifarm faces two key challenges. First, it must ensure high-quality production in regulatory compliance, essential for partnering with reputable companies in the broader region. Second, it must maintain cost control, production efficiency and high productivity to remain profitable. The digitalization of production effectively addresses both challenges, a fact recognized by the company’s ambitious management, which fully supports the systematic modernization of its processes. In partnership with Metronik, Marifarm has implemented several modules from the MePIS family, including the MePIS LS MES system for the pharmaceutical industry.
Solutions
Marifarm’s comprehensive digital transformation is built on four main solution pillars:
- MePIS LS is a Manufacturing Execution System (MES) tailored for the pharmaceutical sector, designed to digitize production processes and manage material flow while recording all events in the production process. Its goal is to generate an electronic batch report (EBR). It defines manufacturing procedures (MBR), guiding operators through digital workflows.
- MePIS OPEX is a platform for monitoring bottlenecks and calculating key performance indicators (KPIs) using the Overall Equipment Effectiveness (OEE) methodology. It has been deployed across all packaging lines to provide real-time monitoring and ensure improved production efficiency.
- MePIS PDM and MePIS RM are the core components of Metronik’s platform, bridging the production process (Level 2) with the MES system (Level 3) in what is known as IT/OT convergence. Beyond this connection, they provide essential features for full production digitalization. MePIS RM manages production recipes, and recipe transfers to production equipment can also be initiated from the MES system. MePIS PDM captures, contextualizes and processes data from production equipment, managing production reports and analytics. It also enables reporting to MES, periodically or automatically, in cases of detected deviations, completing the cycle of end-to-end production digitalization.
- MePIS Energy is the solution for monitoring energy consumption and calculating relevant efficiency indicators. It provides tools for planning and implementing energy-saving measures and optimizing energy-related costs.
- The automation of HVAC and energy systems includes the control and monitoring of mechanical systems (heating stations, cooling stations, compressed air stations, HVAC systems for warehouses, cleanrooms and offices, meters) and electrical systems (switch control, meters) using SCADA (GE iFix, Historian) and PLC (Opto22).
Results
With the introduction of MePIS LS Marifarm has fully digitized its production. By eliminating paper-based operations in packaging, operators are now able to focus more on the production process, which is managed through the application. Data is recorded continuously, and the traceability of material flow is improved through optical recognition, reducing errors and non-compliance issues. Electronic reports are now readily available, along with other significant benefits.
MePIS OPEX provides a detailed view of the efficiency of packaging lines, identifying parts of the process that cause losses and enabling the development of measures to improve performance.
MePIS RM ensures that only approved settings are used on machines, which cannot be altered by operators. Process parameter data from work orders is transferred to MePIS PDM, where it can be analyzed and compared using graphical and tabular displays, allowing for the preparation of GMP-compliant reports.
With MePIS Energy Marifarm can systematically monitor energy consumption and improve the energy efficiency of production processes, lowering associated costs and reducing its carbon footprint.
Additionally, some production data is transferred to the ERP system for financial and material management, eliminating the need for manual data entry.
The HVAC and energy automation solution complies with GMP requirements. The control algorithms for energy systems are designed to ensure high energy efficiency in addition to meeting the required conditions. The quality and reliability of the system are demonstrated by its uninterrupted operation since 2008.
Photography source: Marifarm.si