Predictive maintenance for pharmaceutical plants
How can a pharmaceutical plant keep equipment failures from costing a batch?
DHMSCare monitors centrifuges, circulation and feed pumps, chillers and air compressors.
Wireless vibration and temperature sensors sit on each machine.
A typical production line needs about 30–50 sensors on DMG310 gateways.
Its industrial AI agent flags anomalies in cleanroom equipment early.
It keeps a complete operating log for root-cause analysis and records.
Industry challenges
A centrifuge or air compressor failure in the middle of a batch can cause batch loss. The active pharmaceutical ingredient (API) in that batch is costly to lose.
Anomalies on cleanroom equipment are hard to detect promptly. Periodic manual rounds often catch them too late.
Variations in critical process parameters can affect API quality consistency. Equipment that runs unevenly is one source of that variation.
Centrifuges, pumps, chillers and compressors come from different brands, with different designs and operating modes. Without one health platform, centralised management is hard and maintenance is inefficient.
Quantifiable value
Do you have a case study from a pharmaceutical plant?
Yes. DHMSCare monitors centrifuges, circulation and feed pumps, chillers and air compressors for a global maker of active pharmaceutical ingredients, on the DHMSCare AI Care plan. The rotating equipment it covers there is all on the DHMSCare supported list; published customer cases are listed by industry on the cases page.
Monitoring solution
DHMSCare places sensors on the motors and bearing seats of centrifuges, circulation and feed pumps, chillers and air compressors, whatever their brand.
The sensors are bonded on without modifying the machines, and the gateway is wall-mounted.
From the day of installation, DHMSCare detects anomalies, keeps complete operating logs and produces equipment health reports for your records, with no months-long learning period.
Platform
DHMSCare uses AI to identify early fault signs such as gear wear and bearing anomalies, assess equipment health and provide maintenance recommendations.
Recommended measuring points and plan
What a typical production line needs, so you can see the whole plan before we talk.
| Asset | Suggested sensors | Measuring points (bearing seats) |
|---|---|---|
| Centrifuge | 5 | Motor DE and NDE, plus 3 on the machine’s bearing seats |
| Circulation / feed pump | 4 | Motor DE and NDE, pump DE and NDE |
| Chiller | 4 | Compressor motor DE and NDE, plus 2 on the compressor bearing seats |
| Air compressor | 4 | Motor DE and NDE, plus 2 on the airend bearing seats |
| Gateway | DMG310 | DMG311 (4G) where there is no Wi-Fi |
| Per production line | approx. 30–50 |
Actual quantities are confirmed on site
AI Care
The first plan with AI fault diagnostics, the AI that finds the gear wear and bearing anomalies behind these results.
Choose AI Care Plus for unlimited automatic diagnostics, remaining-life forecasts with Mina Ultra and 24 months data retention.
Smaller teams can start on Care: AI condition monitoring and daily reports with 10 user accounts, then move to AI Care when you need AI fault diagnostics.
Start with one line
The smallest sensible start, then grow line by line or roll out plant-wide.
Watch the machines you can least afford to stop.
You learn about faults days ahead.
All your lines, all sites, on one dashboard.
Tailored to your project's requirements.
Runs on your own servers or private cloud.
Contracted and delivered as a project.
Can DHMSCare monitor HVAC air handlers and purified-water pumps in a pharma plant?
Yes. DHMSCare monitors the fans, motors and pumps inside HVAC air handlers and purified-water systems, and already monitors chillers and pumps at a pharmaceutical plant. Blowers, fans and pumps are all on the supported equipment list.
Questions
We are a small or mid-sized company. Is this for us?
Yes. Start with one line and one gateway, subscribe per sensor per year, and begin on AI Care; Care if you only need condition monitoring.
How long does a one-line pilot take?
Installation follows the seven steps in our quick installation guide: create the equipment, mount the gateway, attach the sensors and bind the measuring points. We agree the pilot period with you by line size.
We have no vibration engineer. Can we still use it?
Yes. The AI identifies early fault signs, assesses equipment health and gives maintenance recommendations, and Mina tells you which machine to handle first and why.
Which equipment should a pharmaceutical plant monitor first?
Start with centrifuges and air compressors, because their failures can cost a whole batch. Then add the circulation and feed pumps and the chillers that hold your process parameters steady.
How many sensors does a pharmaceutical production line need?
About 30–50 per line. That is 5 per centrifuge and 4 each per circulation or feed pump, chiller and air compressor, connected through DMG310 gateways.
Does DHMSCare help with maintenance records for cleanroom equipment?
Yes. DHMSCare keeps complete equipment operating logs, supports root-cause analysis and generates equipment health reports for record-keeping.
View all questions → Help center
Related case studies
Tell us the line and its critical assets; we size the sensors and the plan with you.