Challenge

Before Itanta, readings and operational data were manually collected, recorded, and maintained in Excel. The process was time-consuming and prone to human error.

Outcome

Itanta's Core Platform automatically collects plant process and EMS data from WinCC/SQL, calculates energy consumption, and displays real-time information through dashboards and automatically generated reports.

At a glance

• 1–2 mo — Deployment Timeline
• Real-time — Process & Energy Data
• Automatic — Data Logging
• Core — Platform Deployed

About Cipla

Cipla operates in Pharma & Life Sciences, producing advanced pharmaceutical formulations and oral solid dosage forms across a large organization with 10+ plants.

Industry: Pharma & Life Sciences · Size: Large (10+ plants)

Introduction

Cipla operates in Pharma & Life Sciences, producing advanced pharmaceutical formulations and oral solid dosage forms. The supplied report views cover process, energy, chiller, pump, water-chiller, and other-utility data from Cipla's Goa and Indore operations.

Before Itanta, readings and operational data were manually collected, recorded, and maintained in Excel. This made the process time-consuming and prone to human error, while teams had to wait for manual readings and report preparation before reviewing plant performance.

Itanta's Core Platform was deployed in 1–2 months to automatically collect plant process and EMS data from WinCC/SQL, calculate energy consumption, and present the results through real-time dashboards and automatically generated reports.

The Challenge Before Itanta

Manual readings made process and energy reporting slow and error-prone

• Manual Data Collection: Readings and operational data had to be collected manually from plant systems and equipment.
• Excel-Based Records: The collected information was recorded and maintained in Excel, creating a separate manual reporting process.
• Delayed, Error-Prone Reporting: Manual handling made the work time-consuming and increased the risk of human error while preparing process and energy reports.

Highlights

• Automatic collection of plant process and EMS data from WinCC/SQL
• Energy consumption calculated within the Itanta Core Platform
• Real-time process and energy data available through dashboards
• Automatically generated reports for energy, EMS, chillers, pumps, and utilities
• Manual readings and report preparation reduced, giving the team faster access to plant information

From manual readings and Excel records to real-time process and energy visibility with automatically generated reports.

Solution Architecture

Plant Equipment & Utilities

Water chillers with KPIs, pumps, energy meters, and other utilities provide the plant process and energy data.

PLC, SCADA & VM Workstation

The plant data flows through the Siemens 1200 Series PLC and SCADA to the VM workstation, where WinCC and SQL hold the operational data.

Itanta Core Platform

Itanta collects the WinCC/SQL data, calculates energy consumption, and presents process and energy information through dashboards and reports.

• Data flow: Plant Equipment & Utilities → Siemens 1200 Series PLC → SCADA → VM Workstation / WinCC / SQL → Itanta

What Was Deployed

Itanta connected Cipla's existing plant data environment to a single platform for faster process and energy review.

• Automatic Data Collection: Process and EMS data from WinCC/SQL is collected automatically instead of relying on manual readings.
• Energy Consumption Calculation: The Core Platform calculates energy consumption from the connected plant data and makes the results available for review.
• Real-Time Plant Visibility: Teams can directly access current process and energy data through dashboards rather than waiting for manually prepared records.
• Automated Reporting: Energy, EMS, chiller, pump, water-chiller, and other-utility reports can be generated automatically in less time.

Dashboards & Reports

The supplied views show how Cipla's process, energy, chiller, pump, and utility information is organized for real-time review and reporting.

• Goa Energy Consumption Report: Monthly energy consumption report for Cipla Goa Unit 2, listing chiller energy sources and total energy consumption per day.
• Goa Chiller KPI Report: Chiller KPI view with chiller running load, coefficient of performance, specific energy consumption, condenser effectiveness, evaporator effectiveness, and related measurements.
• Goa Other Utilities Report: Time-based report for cooling-tower, chilled-water, and other utility parameters, with a selected start and end time.
• Indore Energy Hourly Data: Hourly energy data view for incoming, power-centre, air-compressor, and chiller sources with timestamped values and totals.
• Indore Energy Basic View: Basic energy monitoring view for reviewing connected plant energy data in one place.
• Indore EMS Daily Report: Daily Energy Management System report for structured review of plant energy information.
• Indore Water Chiller Report: Water chiller report for reviewing chiller operating conditions and associated process parameters.

Measurable Outcomes

Faster access to reliable process and energy information

• Automatic — Data Logging. Plant process and EMS data is logged automatically instead of being collected manually.
• Automatic — Report Generation. Reports are generated automatically, reducing the effort required to prepare them.
• Real-time — Data Availability. The team can directly access current process and energy data in Itanta.
• Reduced — Manual Readings. Manual readings and report preparation were reduced, and reports can be generated in less time.

Itanta's Impact

The team no longer needed to manually collect readings and prepare reports. They could directly access real-time process and energy data in Itanta and generate reports quickly.

• Manual collection of plant readings was replaced with automatic data logging from WinCC/SQL.
• Process and energy information became directly accessible through dashboards instead of waiting for manual readings.
• Automatically generated reports made daily review faster and reduced the effort involved in report preparation.

Turn Plant Data into Faster Decisions

See how Itanta's Core Platform can connect your process and EMS data, calculate energy consumption, and deliver real-time dashboards and automated reports.