Pharma & Food Production Line
GMP-compliant Data Acquisition & Batch Traceability

II. Core Pain Points

Scattered data, hard integration, broken traceability - three hurdles for compliant digitalization.

• Heterogeneous equipment brands and protocols, high integration cost: On the line, Siemens, Mitsubishi, OMRON, Delta and other PLCs coexist, plus environmental monitoring instruments and energy meters. Generic gateways "cannot well connect" proprietary controllers; per-vendor integration has long cycles and high investment.
• Data silos, broken batch traceability: Process parameters are scattered across controllers, lacking unified acquisition and batch binding; when quality deviation occurs, it is hard to quickly trace back to specific equipment, time and batch.
• Environmental monitoring by manual logging: Key environmental parameters such as clean-area temperature/humidity and differential pressure are still partly logged manually on a schedule, with risks of omission and back-filling, hard to meet real-time, continuous, tamper-proof recording requirements.
• Cumbersome compliance audit preparation: Surprise inspections and audits need quick retrieval of a batch's full parameter curves; the traditional approach relies on manually compiled reports, time-consuming and error-prone.

III. Why Traditional Approaches Fail

Per-vendor custom development + modifying PLC - high in cycle, cost and compliance risk.

• If you ask each equipment vendor for open interfaces or custom development, a single line must integrate N vendors, with months-long schedules; some legacy equipment vendors no longer provide support, often "connecting halfway and getting stuck".
• Directly modifying PLC logic or the upper-computer system, in the pharma / food industry, is a controlled change requiring change approval, validation and re-confirmation processes - affecting the whole body; customers are unwilling to easily take compliance risks.
• Even if a few are barely connected, there is no unified batch data model and upload specification; data enters the database but cannot be used; audits still rely on manually assembled reports.

IV. Solution: AIS-G160 Compliant Data Acquisition

Non-intrusive acquisition of multi-brand PLC and instrument data, bound by batch and uploaded to platform.

• Multi-brand PLC and environmental instrument protocol direct acquisition: G160 connects directly to various PLC and environmental monitoring instruments and energy meters on the line via serial / Ethernet, with a built-in library of 500+ protocol drivers covering mainstream PLC and environmental / building-control protocols; one gateway per equipment type, plug-and-play.
• Non-intrusive, no modification of controlled objects: G160 interfaces with existing PLC and instruments in a read-only / acquisition manner, without changing existing PLC logic, upper-computer systems and process flows, avoiding controlled-change risks; fast deployment and light validation.
• Batch-level data binding: Acquired process parameters and environmental data are structured and bound by batch / work-order dimension, uploaded to MES / DVS, forming continuous, tamper-proof parameter curves, supporting batch traceability.
• Unified upload to MES / DVS: Structured data is uploaded via standard methods such as MQTT / Modbus TCP / OPC UA; key parameters, environmental compliance and alarms on one screen; audits can retrieve a batch's full parameters with one click.
• Compliant deployment: General plants use the workshop management network / 4G; classified or sensitive process stages use private / intranet deployment with 4G not connecting to public networks, meeting security compliance requirements.

VI. Why AIS-G160

The three capabilities "complete protocols + non-intrusive + batch binding" address all demands of compliant acquisition.

• Complete protocols: Built-in 500+ industrial protocol driver library covering mainstream PLC (Siemens, Mitsubishi, OMRON, Delta, Inovance, etc.) and environmental / building-control protocols (CJ/T188, DL/T645, HJ212, BACnet, etc.), with native support for proprietary controllers that generic gateways "cannot well connect".
• Non-intrusive acquisition: Interfaces with existing PLC and instruments in a read-only / acquisition manner, without changing existing logic and upper-computer, avoiding the controlled-change risk of the pharma / food industry; fast deployment and light validation.
• Batch-level data model: Acquired data is structured and bound by batch / work-order dimension and uploaded, supporting GMP audit traceability, environmental compliance and quality analysis - data "can be acquired, bound accurately and traced back".
• Compliant, flexible deployment: Supports workshop management network, private / intranet, 4G and other deployments; sensitive process stages can use private network, meeting industry security compliance requirements.

VII. FAQ

High-frequency questions about "pharma / food GMP-compliant data acquisition".

VIII. PLC (Programmable Logic Controller) Brands & Models Supported by G160

This case centers on G160 acquiring pharma / food line multi-brand PLC. AIS-G160 has a built-in library of 500+ industrial device protocol drivers. The following are mainstream PLC brands and models verified for data acquisition (some models require on-site interface confirmation), serving as a basis for solution selection and field verification.