Challenge

Manual reporting caused delayed visibility and limited centralized process monitoring — batch details, Charge IDs, and process parameters had to be searched and verified manually from different sources.

Outcome

Deployed in 1–2 months: cyclic process data monitoring and batch reporting with Charge ID traceability. Multiple Charge IDs within a batch can be identified and traced, with pressure and temperature checked in just a few clicks.

At a glance

• 1–2 mo — Deployment Timeline
• 1 min — Cyclic Data Interval
• 5 — Equipment Types Reported
• 4 — Report Types Delivered

About DFE Pharma India Private Limited

DFE Pharma India Private Limited produces pharmaceutical excipients and formulation ingredients, operating as a mid-size manufacturer with 3–10 plants.

Industry: Pharma & Life Sciences · Size: Mid-size (3–10 plants)

Introduction

DFE Pharma India Private Limited manufactures pharmaceutical excipients and formulation ingredients, where batch-level traceability and process parameter records are central to daily operations.

Before Itanta, manual reporting caused delayed visibility and limited centralized process monitoring. Tracing the multiple Charge IDs that make up a batch — and verifying the pressure and temperature values associated with each — meant manual searching across different sources.

Itanta's Core Platform was deployed for cyclic process data monitoring and batch reporting with Charge ID traceability. It captures process data from the WinCC SCADA system's SQL Server database, links it with the respective Charge ID, and generates traceable batch reports — delivered within a 1–2 month deployment timeline.

The Core Challenge Before Itanta

Manual reporting delayed visibility into process and batch data

• Manual Reporting: Reports were prepared manually, causing delayed visibility into cyclic process data and batch information.
• Limited Centralized Monitoring: There was no centralized way to monitor process data — parameters had to be checked from different sources.
• Time-Consuming Verification: Tracing Charge IDs within a batch and verifying process parameters such as pressure and temperature required manual searching and cross-checking.

Highlights

• Cyclic process reports generated automatically at a 1-minute interval for equipment such as WDT, GLR, STT, RFT, and RVDF
• Batch reports clearly show multiple Charge IDs within the same batch
• Pressure and temperature for each Charge ID checked in just a few clicks
• Process data captured from WinCC SCADA's SQL Server via Itanta Data Source Manager
• Charge Report ties each Charge ID to its equipment, start/stop times, and identification parameters

From manual searching across different sources to automatic cyclic reports and one-place Charge ID traceability — deployed in 1–2 months.

Solution Architecture

Process Data & WinCC SCADA

Process data from the plant flows into the WinCC SCADA system, where it is stored in the SQL Server database.

Itanta Data Source Manager

Itanta's Data Source Manager connects to the WinCC SCADA SQL Server database and streams the process data to the Itanta Platform.

Itanta Platform

The Itanta Platform links captured process data with the respective Charge ID and serves cyclic process reports, charge reports, and traceable batch reports.

• Data flow: Process Data → WinCC SCADA (SQL Server) → Itanta Data Source Manager → Itanta Platform

What Was Deployed

Itanta's Core Platform captures process data from the WinCC SCADA SQL Server database and links it with the respective Charge ID — delivering four capabilities:

• Cyclic Process Reports: Automatic reports at a 1-minute interval for process equipment — WDT, GLR, STT, RFT, and RVDF — covering values such as temperature, pressure-based vent parameters, and header steam pressure with PV, SP, and MV columns.
• Charge ID Traceability: Each charge is identified with its recipe, lot number, Charge ID, dispersion tank, GLR, STT, RFT/RVDF, and settler details along with start and stop times.
• Traceable Batch Reports: Batch reports list every charge within a batch with parameters such as HCL quantity, reaction time, reaction temperature, reaction pressure, settling time, and water quantities — against max/min tolerances.
• Batch-Level Visibility: Along with each Charge ID, process parameters such as pressure and temperature can be checked in just a few clicks, reducing manual verification effort.

Reports Delivered

Itanta delivered cyclic process reports for the plant's process equipment plus charge and batch reports, giving the team one place to review process data and trace every Charge ID within a batch.

• WDT Report: Cyclic report for the wood pulp dispersion tank (WDT-2310) at a 1-minute interval — header steam pressure and temperature with PV, SP, and MV values.
• GLR Report: Cyclic report for the glass-lined reactors (GLR-1110 to GLR-1140) at a 1-minute interval — temperature and pressure-based vent parameters per reactor.
• Charge Report: Charge identification parameters for each Charge ID — recipe number and name, lot number, dispersion tank, GLR, STT, RFT/RVDF, and settler numbers with start and stop times.
• Batch Report: All charges within a batch in one table — wood pulp quantity, HCL quantity, reaction time, temperature and pressure, settling time, and water flows against max/min tolerances.

Measurable Outcomes

Batch-level visibility with less manual verification effort

• Multiple — Charge IDs Traced per Batch. Multiple Charge IDs within a batch can be easily identified and traced
• Few clicks — Parameter Checks. Pressure and temperature for each Charge ID checked in just a few clicks
• Reduced — Manual Verification. Manual data searching and verification effort was reduced
• 1–2 mo — Deployment Timeline. Deployed on the Itanta Core Platform in 1–2 months

Itanta's Impact

Day-to-day work became easier — cyclic process data, batch details, Charge IDs, pressure, and temperature values can be checked quickly from the system.

• Cyclic process reports are generated automatically instead of being prepared manually.
• Batch reports clearly show multiple Charge IDs within the same batch, with related process parameters such as pressure and temperature in one place.
• The team first saw real value when cyclic data review, batch verification, and Charge ID traceability became faster — with manual searching from different sources reduced.

Make Every Batch Traceable

See how Itanta's Core Platform can turn your SCADA data into automatic cyclic reports and Charge ID–traceable batch reports — deployed in as little as 1–2 months.