Case Study: Bayer achieves reduced revalidation effort with ProLeiT Plant Direct iT

Bayer - Customer Case Study

Bayer, a major global pharmaceutical corporation, was faced with the challenge of replacing an obsolete operator control and monitoring system in one of its agent production plants without triggering a full revalidation of its manufacturing process. The complex project had to be completed with production running at high capacity, requiring minimal requalification expenditure and the shortest possible installation duration. After an intensive evaluation, Bayer selected the innovative Plant iT process control system from vendor ProLeiT to meet these strict requirements.

The solution implemented by ProLeiT used the Plant Direct iT component, an open, component-based system that utilized new SIMATIC S7 controllers to communicate with the existing field devices. A key feature was the development of project-specific, reusable software classes that mirrored the existing system's functions, which drastically reduced engineering and validation effort. Through meticulous planning, extensive testing, and close cooperation, ProLeiT successfully completed the migration on time. The result was a new, efficient control system that met all regulatory requirements, minimized revalidation costs, and allowed for future upgrades, all while production was largely unaffected.

Bayer