The pharmaceutical and semiconductor industries face increasing pressure to manage ultrapure water (UPW) and steam systems efficiently, ensuring safety while minimising operational risks. Failures in these critical systems can result in costly downtime and inefficiencies. boTec, in collaboration with gat GmbH, offers a cutting-edge solution that combines automated monitoring, control systems, and advanced simulations. Our data-driven models optimise the management of UPW, including Water for Injection (WFI) and Purified Water (PW), along with steam systems, ensuring safe, reliable, and efficient performance while reducing risks and improving operational outcomes.
Challenges in Ultrapure Water Management
Overcoming the complex challenges in ultrapure water management requires balancing purity standards, scalability, energy efficiency, system reliability, and strict regulatory compliance.
- Maintaining Water Purity
Ensuring that ultrapure water systems consistently meet strict purity requirements is a major challenge. Even minimal contamination can lead to severe consequences, such as production downtime, product quality issues, or regulatory non-compliance. - Scaling Without Compromising Efficiency
As demand for UPW grows, scaling operations without introducing inefficiencies or increasing the risk of contamination is difficult. Poor planning during expansions can lead to costly operational disruptions. - Energy Consumption
UPW systems are highly energy-intensive, particularly in processes that require large volumes of purified water or steam. Balancing energy use with operational efficiency is a constant challenge. - Long-Term System Reliability
The continuous operation of UPW systems places stress on equipment, leading to wear and tear over time. Unplanned maintenance or system failures can cause significant downtime, disrupting production and increasing costs. - Regulatory Pressures
Both pharmaceutical and semiconductor industries face rigorous and evolving regulatory standards. Ensuring compliance with these standards while managing the complexity of UPW systems requires constant monitoring and adaptation.
Planning & operation of storage and distribution systems
Achieve efficient management of storage and distribution systems through real-time automation, advanced simulation and comprehensive lifecycle optimisation to ensure operational integrity and minimise risk.
- Real-Time Automation
Our solutions continuously monitor operational conditions, identifying and preventing critical issues such as pressure drops or flow inconsistencies. By responding proactively, we ensure uninterrupted and safe system operation, reducing the risk of failure. This intelligent tapping point management ensures optimal resource distribution, helping maintain operational integrity. - Dynamic and Static Simulations
Our advanced simulation tools allow businesses to model system performance in both dynamic (real-time) and static environments. Dynamic simulations are connected to live system data, providing real-time feedback and enabling immediate adjustments to optimise operations. Static simulations, on the other hand, allow businesses to model future scenarios, ensuring precise planning, risk mitigation, and optimisation of operational workflows without interfering with current activities. - Comprehensive Lifecycle Management
We optimise every stage of the system’s lifecycle, from installation through to daily operations. Our comprehensive approach ensures long-term reliability and efficiency, minimising downtime and operational costs while maximising system performance throughout its lifespan.
Business Outcomes
Real-time control, predictive simulation and scalable system management reduce costs, increase safety and improve efficiency.
- Cost Reduction
By integrating real-time control and predictive simulations, our system minimises inefficiencies and helps prevent system failures. This proactive approach leads to significant savings in operational expenses and reduces the overall cost of ownership. - Enhanced Safety and Compliance
Our fully automated control systems ensure that critical processes are managed with complete transparency, helping clients maintain regulatory compliance while improving safety. Predictive control features based on priority classes further ensure the safe and efficient operation of your system. - Improved Efficiency and Scalability
Our simulation models allow businesses to plan for future expansions or modifications without disrupting ongoing operations. This ensures seamless scalability, whether managing water purification systems for pharmaceuticals or increasing capacity in semiconductor production.
Find out how boTec and gat GmbH are using advanced automation and simulation to improve ultrapure water and steam systems in the digital flyer (hosted on gat’s website in German).
Our Differentiators
Our solution is designed to predict and prevent operational risks, ensuring safe, efficient, and scalable management of these critical systems. This seamless integration boosts business productivity while significantly reducing costs throughout the system’s lifecycle.
Integrated Automation and Simulation
Predictive Flow and Pressure Monitoring
Comprehensive Lifecycle Optimisation
Scalable System Management
Our participation in PharmaTechnica 2024 in Wiesbaden and LOUNGES 2024 concluded on a high note, where we proudly showcased our collaborative planning and monitoring solutions. We’ve summarised the key experiences and insights gained from these events in a detailed update on our LinkedIn post and blog post.
If you’d like to learn more, feel free to reach out—we’d be happy to share further details and answer any questions you may have
