Modernise existing equipment for modern pharmaceutical manufacturing.
Extend equipment life. Improve operator experience. Support 21 CFR Part 11, GxP and modern validation expectations — without replacing your existing systems.
Before
Older control systems
- Obsolete PLCs and HMIs
- Spare parts becoming scarce
- Paper-based batch records
- No audit trail or e-signatures
After
Modern, compliance-ready
- Current-generation PLC and HMI
- Long-term parts availability
- Electronic batch records
- Audit trails and e-signatures
Keep your validated mechanical equipment. Upgrade only what needs to evolve.
Mechanical equipment that still works. Controls that haven't kept up.
As pharmaceutical manufacturing requirements evolve, older control systems can become a limitation. The mechanical equipment may still be robust and suitable for production — but the controls create issues around compliance, spare parts availability, operator usability, data integrity, validation expectations and long-term reliability.
A control upgrade lets you extend the life of existing equipment without investing in a completely new system.
What an upgrade can include
New PLC hardware
Replace obsolete components with current-generation control architecture for long-term reliability.
Updated HMI screens
Modern operator interfaces with improved usability and clearer process information.
Improved batch controls
Recipe management, parameter control and improved process repeatability.
User access levels
Role-based access aligned with operational responsibility — operator, supervisor, QA.
Alarm handling
Clearer alerting, prioritisation and acknowledgement — designed around operator workflow.
Data recording & trending
Historical trending and validated record capture for process insight and QA review.
Recipe management
Secure, version-controlled product recipes with change management built in.
Audit trails
Full, tamper-resistant logging of operator and system actions — 21 CFR Part 11 ready.
Reporting & export
Batch records and process data exported in formats QA and validation teams can use directly.
Key benefits
Extend the working life of existing equipment
Get more years from systems you've already validated and embedded into your process.
Improve operator control and usability
Modern HMIs reduce training time and operator error across shift patterns.
Support 21 CFR Part 11 and data integrity
Audit trails, electronic signatures and role-based access designed in.
Reduce obsolescence risk
Replace ageing PLCs before parts availability becomes a production problem.
Improve batch consistency
Modern controls deliver tighter process control and repeatable outcomes.
Avoid full replacement cost
A fraction of the cost of new equipment, with substantially less production downtime.
Applications Support
Terriva doesn’t only supply and upgrade equipment — we help customers understand how that equipment fits their process, compliance requirements and production environment.
Scope the right project
Define what to upgrade and what to leave — calibrated to your operational and regulatory context.
Work with your teams
Engineering, validation and QA collaboration through specification, install and sign-off.
Validation path planning
URS, FAT, SAT documentation aligned with your validation framework from day one.
Compliance alignment
Every Terriva controls upgrade can be specified to support the regulatory frameworks pharmaceutical manufacturing depends on.
- 21 CFR Part 11: FDA-regulated e-records and signatures
- GxP: Good Practice across regulated pharma
- GAMP: Risk-based validation of automated systems
- Data integrity: ALCOA+ principles in process records
Next steps
Considering a controls or software upgrade?
Our team will scope the right project for your equipment, your compliance environment and your operational priorities.
