P-E-T Process Equipment Tracking - RFID Tracking and Lifecycle Analysis System from Verigenics

P•E•T Process Equipment Tracking® offers a new degree of safety and reduced risk for the pharmaceutical processing industry, as well as other high purity applications in the food and beverage, cosmetic, chemical, and biomedical sectors. Using RFID (radio frequency identification) technology, all process equipment involved with a particular batch of product is monitored from start to finish. Track usage and cleaning cycles to ensure timely maintenance and replacement . . . before parts begin to fail, risk product integrity, and waste time and labor. Briefly stated, you can track who did what to each batch and when. It's a logical approach to tracking all critical process components.

PROCESS EQUIPMENT APPLICATIONS
TYPICAL CONFIGURATION
POSSIBLE ATTACHMENT METHODS

P•E•T ADVANTAGES

Identifies individual process equipment devices such as pumps, bio-bags, diaphragm valves, filters, UV lamps, and hoses using RFID tags
Tracks key wear-related events such as cleaning cycles/dates and batches of material processed or other user-defined events
Ensures timely maintenance and replacement before parts begin to fail, risk product integrity, and waste time and labor
Provides an audit trail to assist in validation processes; helps accelerate data collection procedures and lower costs
Reduces errors on the production floor
Consolidates documents by electronically linking to notes, cleaning schedules, files, certifications, photos and illustrations, installation instructions, warning notices, and other protocols
Safe for use with CIP, SIP, and autoclave processes
Various tags address applications involving high temperatures, gamma irradiation, and mounting to metal
Gamma-radiation-resistant RFID tag – GammaTag® – now available
Different tag sizes and shapes available
Field installation methods available to immediately start tracking existing equipment
U.S. Patents 7,195,149; 7,328,837 and 8,519,846

ADVANTAGES

Minimizes Risk

Tags are encoded with serial numbers and other information and are externally attached to each piece of process equipment – no contact with material flow
An administrative level access, known as Kiosk mode, prevents changes to the system – restricts usage to help enforce 21 CFR Part 11 validation
Identifies individual process equipment parts such as hoses, pumps, bio-bags, diaphragm valves, filters, and UV lamps using RFID tags
A fast, efficient, and precise identification system for critical process equipment
Eliminates dependence on manual log book record keeping, its inefficiencies and inaccuracies, and the books' contribution as a contamination source

Reduces Costs

Accesses and records the current status of any tagged component on the spot
Reduces errors on the production floor
Limits failures and helps calculate equipment life expectancy using actual data
Eliminates the inefficient calendar method of swapping out used parts – reduces wasted production life and underutilized equipment
Field installation methods available to immediately start tracking existing process equipment
Applicable to predictive maintenance systems (PdM)

Consolidates Documents

Eliminates inefficient paper labels and hang tags
Reduces dependency on paper records and their inherent problems, such as transposed numbers, incorrect dates, handwriting legibility, misread data, and misfiled documents
Electronically links to notes, cleaning and maintenance schedules, files, certifications, photos and illustrations, installation instructions, warning notices, and other protocols
Allows recording and storage of all critical information
Links to a database that contains the complete biographical history of parts
Allows information access from any networked computer running the Hose Track program

Provides an FDA Audit Trail

Third-party validated for 21 CFR Part 11
Speeds audits and lowers their costs by eliminating the time and labor of locating, retrieving, and gathering paper records and traditional log books
Tracks key wear-related events such as cleaning cycles/dates, batches of material processed, calibration, and other user-defined events
Provides a secure, tamper-proof record to track time, date, and operator data

Easy to Use

Unlike bar code labels, tags do not require a clear sight line for reading/writing
Safe for use with CIP, SIP, and autoclave processes
Integrates with existing workflows
Custom engineered to best meet individual needs
Select the tag attachment method best suited for each particular item – choose from a molded pouch, lamination, watchband style encasement, silicone fusible tape, or any customized design

RFID Tracking Used In Process Equipment Applications
Calendar & Manual Log Methods For Replacing Critical Process Components Can Be Unreliable, Increasing Risk Of Product Contamination & Wear Related Failure
RFID Tags Attached To Process Equipment Are Scanned By Reader/Writer To Track Wear Related Events & Update Computer Database
Process Equipment Identification and Lifecycle Analysis System Provides An Audit Trail To Assist In The Validation Process

TYPICAL CONFIGURATION

RF Identification Attachment Methods	Portable Handheld Reader/Writer	Lifecycle Analysis Tool
The RFID tag is attached to each device and encoded with a unique serial number. Several attachment methods are available and include a molded pouch, lamination, stainless steel strap, silicone fusible tape, complete silicone encasement, etc. Many of these methods allow tag attachment to process equipment currently installed in facilities. Tag encoding can be customized to meet specific needs.	The handheld reader/ writer identifies each device by its serial number for reference in a database. The reader/ writer logs and tracks ongoing wear-related events such as the number of cleaning cycles and dates performed (CIP, SIP, autoclave), and the number of batches of material processed. Data is programmed back onto the RFID tag and later downloaded to a database for analysis.	Specific data is transferred to a local computer using the Lifecycle Analysis Tool (software) to catalog process equipment, maintain wear-related events, and store application data associated to a particular location. Personnel can perform lifecycle analysis for individual locations for an accurate, application specific replacement schedule prior to excessive degradation or failure.

POSSIBLE ATTACHMENT METHODS

A wide variety of process components exist in various shapes and sizes creating a need for different attachment methods. The AdvantaPure engineers are up to the challenge of attaching RFID tags to your components and are ready to work with you to design something that fits your specific requirements.

Our development of the Hose Track System has given us extensive experience with hose attachment methods. For example:

...silicone injection molded to the O.D. of a hose assembly	...wrapped silicone fusible tape for use with existing hoses	...plastic tie-wrap for use with existing hoses

Using a diaphragm valve as an example, different means could be employed to place an RFID tag onto the component such as:

...a plastic pouch and wire tie	...integrated into bonnet design

Many more applications exist and other solutions can be further developed. What works for you?

...a tag holder could be attached to a filter housing using a stainless steel strap	...a pouch can be affixed to the exterior of a biobag	...a mounting block could be fastened to the exterior of a mixing vessel

Contact your Verigenics representative today to see how P•E•T Process Equipment Tracking can solve your needs at: Phone: 215-526-2180 • Toll Free Phone (US only): 888-323-5131

Click the link to download a printable version of our P•E•T Process Equipment Tracking brochure. PET_Process_Equipment_Tracking.pdf (1.2MB)

P•E•T Process Equipment Tracking^®

RFID PROCESS EQUIPMENT TRACKING & LIFECYCLE ANALYSIS SYSTEM