Fine chemistry: batch reactors, safety, MES

Fine chemistry: modernizing without breaking the run.

Automation reinforcement for fine chemistry and specialty producers in Switzerland. ISA-88 batch reactors, MES integration, SIL2/SIL3 functional safety, PCS7 migration. Proven experience at Sun Chemicals and Swiss industrials.

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Field reality

Chemistry-specific challenges

SIL functional safety: critical loops (reactors, ESD valves) must comply with IEC 61508/61511. Any change impacts SIL analysis and HAZOP documentation.

ISA-88 batch reactors: complex recipes, per-product parameterization, material traceability. Poorly designed S88 architecture = major technical debt.

Legacy PCS7 / DeltaV migration: moving from v7/v8 to v9 on in-service reactors requires a rigorous plan to avoid production loss.

Ex / ATEX zones: interventions in explosive atmospheres require certified equipment and specific procedures.

Our method

Our chemistry approach

We combine PLC/DCS expertise with process constraint understanding. For safety modifications, we work closely with your process engineering and HSE to validate SIL impact before intervention. For PCS7 migrations, we propose a phased plan with runbooks and maintenance windows.

Technical stack used

Technologies we master in this sector

Siemens PCS7
Emerson DeltaV
Siemens SIMATIC Safety
Rockwell GuardLogix
ISA-88 batch
ISA-95 MES integration
IEC 61508 / 61511 SIL
ATEX zones Ex
Versiondog
PILZ safety

Project evidence

Assignment from Tai Van's career

Sun Chemicals

Automation of the new raw material introduction process with Power BI, RPA and Power Automate. Workflow mapping, documentation and training.

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Related services

Our services for this sector

Industrial automation and PLC/SCADA integration

Vanguard Systems delivers industrial automation projects in French-speaking Switzerland, from engineering to PLC/SCADA programming, testing and commissioning. We work with Siemens, Rockwell, Beckhoff and Emerson on new projects, retrofits and migrations. The project can connect instrumentation, control and energy supervision, with documentation and support after handover within the agreed scope. On special machines, we take the automation, electrical and integration scope; the mechanics stay with the builder or your teams. Work, interfaces and responsibilities are defined before the project starts. A senior automation engineer can also reinforce your engineering office.

Qualification and validation (CQV)

Complete support for qualification and validation in GMP environments: Factory Acceptance Test, Site Acceptance Test, installation, operational and performance qualification. GAMP5 and 21 CFR Part 11 compliant documentation, deviation management, support for Big Pharma internal audits and authority inspections.

Industrial Data and AI

Practical application of data and AI to real industrial problems: process optimization, predictive maintenance on historian data, on-premise technical chatbots based on RAG, MLOps in regulated environments. Pragmatic approach, no experimental demos: everything we deploy must work in operation and survive a quality audit.

Frequently asked

FAQ: fine chemistry

Can you work on an obsolete PCS7 V7 without breaking it?

Yes. We routinely work with PCS7 v6/v7, knowing the limits (Windows compatibility, end-of-life Siemens support). For v9 migration, phased plan with rollback ready.

Do you work with DeltaV?

Yes, DeltaV is part of our chemistry stack.

Do you have SIL analysis and safety modification experience?

Yes, we work jointly with your HSE and process engineering to validate the SIL impact of any change. HAZOP, LOPA documentation and SIL tests included in the deliverable.

Other sectors

Explore other sectors we serve

Pharma & life sciences

Microtechnology & watchmaking

Food & beverage

Energy & utilities

OEMs & special machines

Contact

Let's discuss your fine chemistry project

Initial response within 4 hours from 07:00 to 19:00, every day. Accepted urgent request: intervention within 48 hours. Scope provided by quote.

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