Flavors & Fragrances Processing Plant

Solution:Process Automation Control System (PAC) in the Flavors & Fragrances facility’s production block
Location:Ranjangaon, Pune.
Type:Greenfield plant setup with Rockwell Automation’s PLC-based control systems.


The plant is divided into Utilities area, Admin block, Warehouse & Production block – Blending, Liquids, Spray Dryers, UF-RO, STP and HVAC.

To meet the FDA requirements and to replace a manual system, the S88 standard of the Instrumentation, Systems, and Automation Society (ISA) defines a common set of models and terminology that can be used to describe and define batch manufacturing systems in accordance with GMP.

Scope of work

Includes complete plant integration and centralise DCS with virtualisation of four Application Servers for different areas like production & utility, Historian Server, Asset Center & Disaster Recovery Server, Vantage Point, Directory server and Thin Manager Server to boost productivity, enhance visualization, extend security and provide smart mobility.

Capability of Plant Control System

  • Graphical view and control of the system to the operator
  • Batch records and reports
  • Process data monitoring
  • Recipe control and configuration
  • Security and safety
  • Utility controls, measurements, monitoring and EMS records
  • Historical and real-time data monitoring and reports
  • Alarm events, sequence events, audit logs, e-signature
  • Dashboards and disaster recovery


  • Batch process control
  • Process reports, audit logs and reports
  • Zone-1 Thin Clients
  • Reduction in regulatory compliance cost
  • Multi-monitor, shadowing, terminal to terminal shadowing
  • Session tiling, session scaling, virtual screens, keypad
  • WinTMC, Virtual Machine Support, PXE Boot Thin Clients
  • Active directory, IP cameras, Applinks
  • Remote monitoring and control
  • High availability, better asset utilization
  • Improved productivity, Increased lifetime
  • Increased system flexibility and technical risk mitigation
  • Reduced maintenance cost
  • Improved efficiency
  • Safety, reliability, minimum Shutdown

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