Automating Recipe Verification to Strengthen Compliance and Efficiency

Manual verification limiting efficiency and increasing risk

As a large pharmaceutical manufacturer producing multiple products on site, the client was required to verify process parameters for each product across manufacturing equipment as part of its quality control system.

This verification process was entirely manual. An operator had to walk throughout the facility, confirm parameter values on local HMIs, and record them on paper documents. The process was repetitive, time consuming, and exposed the business to the risk of human error.

Beyond the resource burden, the company needed a solution capable of parsing multiple product documents and connecting to different manufacturing systems. The future setup also had to include role-based access control, a full audit trail of all system activities, and structured reporting capabilities.

A digital solution for automated recipe verification

Working closely with the client, NNIT designed and implemented a web-based application tailored to the regulated pharmaceutical environment.

Users log in using their Active Directory accounts and upload a validated recipe document. After specifying the IP configuration of the relevant equipment, they initiate an automated verification process.

The application compares recipe values from the document with values read directly from the PLC-controlled equipment. Any discrepancies are clearly highlighted in the user interface using colour indicators. Users can annotate deviations and document whether they are acceptable or require further action.

All results are stored in a central SQL database, ensuring full traceability and enabling reporting for each verification run.

From two days to twenty minutes

The automated solution fundamentally changed the client’s verification process:

• Verification time reduced from approximately 48 hours to 20 minutes.

• Annual time savings of 572 hours.

• Estimated annual engineering cost savings of approximately €51.5K (based on €90/hour).

• Reduced risk of human error and potential product recalls.

With a fully validated solution built on a robust application architecture, the client achieved faster verification cycles, improved compliance documentation, and a scalable digital foundation for future manufacturing needs.