Explore Our Achievements
At A & S Automations, we pride ourselves on delivering cutting-edge solutions across various industries. Our projects showcase our unwavering commitment to precision, innovation, and client satisfaction, all while adhering to the highest industry standards, including stringent 21-CFR compliances.
PW Water Generation Plant - Windlas Biotech Ltd.
Capacity - 5000 LPH.
Site-6, Selaqui, Dehradun
Supplied and commissioned a 5000 LPH Pure Water (PW) generation plant with a robust loop line distribution system, featuring highly accurate instrumentation and 21-CFR compliance.
Project Duration: 2 months
Project Overview
A & S Automations proudly undertook the crucial task of supplying and commissioning a state-of-the-art Pure Water (PW) generation plant with a capacity of 5000 LPH (Liters Per Hour) for Windlas Biotech Ltd. at their Site-6 in Selaqui, Dehradun. This project was a testament to our commitment to precision, efficiency, and stringent regulatory compliance within the pharmaceutical industry.
The core of this system involved not just the generation of high-purity water but also its seamless distribution through a meticulously designed loop line distribution system. We deployed highly accurate instrumentation throughout the process to ensure every parameter was precisely monitored and controlled. Our adopted control philosophy was meticulously crafted to maintain a consistent return flow velocity of 1.2m/sec, a critical factor for preventing biofilm formation and ensuring water quality integrity.
A key highlight of this project was its full adherence to 21-CFR compliances. This included robust electronic data logging, comprehensive alarm monitoring, and precise event recording capabilities. Furthermore, we integrated a customized live report printing system, providing Windlas Biotech Ltd. with immediate access to critical operational data and compliance records. This ensures not only operational excellence but also audit readiness at all times.
The successful completion of this project within a tight two-month timeframe underscores our team's expertise in delivering complex automation and water treatment solutions efficiently and effectively, meeting the high demands of the pharmaceutical sector.
Key Project Highlights
5000 LPH PW Plant
High-capacity Pure Water generation ensuring continuous supply for operations.
Loop Line Distribution
Optimized system for efficient and stable PW distribution across the facility.
Precise Instrumentation
Integration of highly accurate sensors and controls for critical parameter monitoring.
1.2m/sec Flow Velocity
Advanced control philosophy to maintain optimal return flow velocity for hygiene.
21-CFR Compliance
Full adherence to electronic records, data integrity, and audit trail requirements.
Custom Live Reporting
Real-time data and customized report generation for operational insights.
Project Gallery
Upgradation of Water System PLC & SCADA at Shreya Life Sciences.
Capacity - 6000 LPH.
Bhagwanpur, Roorkee
A & S Automations recently executed a complete modernization of the Purified Water / Pharma Utility Automation System at Shreya Life Sciences, replacing the legacy PLC and outdated SCADA platform with a Schneider Electric PLC and a newly developed SCADA system on AVEVA Edge 2020. The project involved advanced engineering, 21 CFR–aligned design philosophy, and full synchronization of all system components for high reliability, compliance, and operational efficiency
Project Duration: 15 Days
Project Overview
A & S Automations recently completed a comprehensive upgrade of the Water System Automation at Shreya Life Sciences, transitioning the facility from an outdated control setup to a fully modernized platform built on Schneider Electric PLC technology and AVEVA Edge 2020 SCADA. This project required detailed reverse engineering of the existing control logic, mapping of all field instrumentation, and the development of a new automation architecture that aligns with strict pharmaceutical manufacturing requirements. The objective was not only to replace old hardware and software but to redesign the system for higher reliability, smarter control, and long-term scalability.
A major highlight of the upgrade was the development of a 21 CFR Part 11–aligned SCADA environment, ensuring full compliance with data integrity, audit trail, and electronic records expectations. The new SCADA interface includes secure login management, operator role classification, complete alarm monitoring, historian trends, CIP/sanitization cycle monitoring, and user-friendly graphics. The PLC program was rebuilt using advanced logic structures, enabling flawless synchronization between RO units, storage tanks, pumps, distribution loop equipment, and all associated utilities. These controls allow the system to run smoothly in AUTO mode, reducing the need for manual supervision and eliminating the risk of human error.
The project was executed with significant operational criticality due to the essential role of purified water in pharmaceutical manufacturing. A & S Automations ensured zero process downtime, implementing a phased migration strategy that allowed the plant to continue water production throughout commissioning. Detailed validation, loop checking, safety interlock verification, and communication testing were performed at every stage to ensure robust and fail-safe operation. The improved alarm diagnostics, equipment health monitoring, and fault-handling logic now provide plant operators with immediate visibility and faster response capability.
With this upgrade, the water system at Shreya Life Sciences is now equipped with a future-ready automation platform capable of supporting expansions, advanced analytics, and digital integration requirements. The modular coding architecture, structured SCADA design, and scalable PLC hardware ensure easy maintenance and adaptability for years to come. By delivering a secure, compliant, and highly efficient automation system, A & S Automations has demonstrated its expertise as a trusted partner for pharmaceutical utilities, offering engineering excellence, regulatory consistency, and reliable control solutions designed for long-term operational excellence.
Key Project Highlights
Zero Downtime Migration Plan
✔Executed without interrupting production purified water supply.
✔Performed stepwise cutover with parallel validation & testing.
Enhanced Data Integrity
✔Compliant electronic logs and audit trails reduce manual paperwork.
✔Secured system ensures tamper-proof records for QA & FDA audits.
Higher Operational Efficiency
✔Auto mode reduces operator dependency and human error
✔Intelligent logic ensures stable water quality & consistent loop performance
Future-Ready Automation Platform
✔Modular SCADA screens & design support expansion of plant utilities
✔System scalable for additional units, additional validation requirements, or IoT connectivity
Improved Safety & Equipment Protection
✔Real-time diagnostics and fault isolation logic minimize damage risk and prolong equipment life
✔Advanced interlocks and permissive checks prevent incorrect operation and safeguard critical equipment
Strengthened Compliance & Audit Readiness
✔Centralized reporting, trend analysis, and system event logging streamline QA reviews and audit preparedness
✔System design aligns with GMP, GAMP 5, and pharma water validation requirements, reducing regulatory non-compliance risks
Project Gallery
PW & WFI Distribution Systems - Laborate
Capacity - 6000 LPH.
Ponta, Himachal Pradesh
Designed and commissioned two advanced distribution systems for PW & WFI with highly accurate instrumentation and full 21-CFR compliance for data monitoring and reporting.
Project Duration: 16 Days
Project Overview
Supplied and commissioned two distribution systems for PW & WFI, each equipped with highly accurate instrumentation. The system incorporates the best control philosophy to maintain return flow velocity at 1.2m/sec, meeting all 21-CFR compliances for electronic data/alarm/event monitoring, recording, and customized live report printing.
This project focused on creating a robust and reliable infrastructure for both Pure Water and Water For Injection, critical for pharmaceutical manufacturing processes. Our solution ensured precise control over water quality parameters and operational efficiency, significantly contributing to Laborate's production capabilities and regulatory adherence.
Key Project Highlights
Dual Distribution Systems
Separate systems for PW and WFI, ensuring specialized purity levels.
Advanced Control Philosophy
State-of-the-art controls for optimal system operation and stability.
Real-time Monitoring
Continuous monitoring for immediate data insights and performance tracking.
cGMP Adherence
Design and implementation compliant with Current Good Manufacturing Practices.
Project Gallery
PW Storage Tank with Distribution System - Ambe Phytoextracts Pvt Ltd
Capacity - 5000 LPH.
Jamariya, Pauri Garhwal, Uttarakhand
Supply and commissioning of a 5KL Pure Water storage tank integrated with a robust distribution system, ensuring a consistent supply of high-purity water.
Project Duration: N/A
Project Overview
Successfully supplied and commissioned a 5KL Pure Water (PW) storage tank seamlessly integrated with a robust distribution system for Ambe Pycoextracts Pvt Ltd in Jamariya, Pauri Garhwal, Uttarakhand. This critical infrastructure ensures a consistent supply of high-purity water, which is essential for sensitive pharmaceutical processes. The entire system was implemented adhering to all relevant industry standards and stringent regulatory requirements.
Our solution provided Ambe Pycoextracts with a reliable and compliant pure water storage and distribution system, optimizing their production efficiency and ensuring product quality.
Key Project Highlights
5KL Storage Capacity
Ample Pure Water storage capacity to meet operational demands.
Integrated Distribution
Seamless supply of high-purity water to all designated points.
Quality Assurance
Ensuring water quality meets pharmaceutical standards consistently.
Regulatory Adherence
System design and installation compliant with all industry regulations.
Project Gallery
PW Distribution System - Supermax Drugs
Capacity - 4000 LPH.
Bhagwanpur, Roorkee, Haridwar, Uttarakhand
Comprehensive Pure Water (PW) distribution system with accurate instrumentation, advanced control philosophy, and full 21-CFR compliance for monitoring and recording.
Project Duration: N/A
Project Overview
Supplied and commissioned a comprehensive Pure Water (PW) distribution system for Supermax Drugs in Bhagwanpur, Roorkee, Haridwar, Uttarakhand. This system features highly accurate instrumentation and a sophisticated control philosophy designed for optimal performance. The system strictly maintains a return flow velocity of 1.2m/sec, ensuring full compliance with 21-CFR regulations for monitoring and recording all electronic data, alarms, and events.
This project significantly enhanced the operational reliability and regulatory compliance of their pure water distribution processes, providing Supermax Drugs with a state-of-the-art solution for their critical needs.
Key Project Highlights
Robust Distribution Network
Efficient and reliable delivery of pure water across all production points.
Comprehensive Data Logging
Automated electronic data, alarm, and event recording for compliance.
Velocity Control
Precision control to maintain 1.2m/sec return flow velocity for hygiene.
Audit Readiness
System designed to meet and exceed all 21-CFR compliance requirements.
Project Gallery
Let's Build Your Next Success Story Together
Our journey thrives with our valued clients as we shape the future of industry, delivering solutions that are not just functional but also future-ready and compliant with the highest standards. Ready to start your project?