Novartis Boosts Plant Flexibility and Operator Efficiency with Emerson’s Wireless DeltaV System

Emerson Process Management’s plant‑wide wireless network is transforming the Novartis biopharma facility in Huningue, France. By integrating its DeltaV digital automation platform with a robust Wi‑Fi system and mobile operator stations, the plant now delivers real‑time process data to both operators and maintenance crews, boosting efficiency and flexibility across the entire site.

Novartis, one of the world’s largest and most respected pharmaceutical companies, employs more than 300 staff at Huningue. The site manufactures the active ingredient for Xolair, a biologic used to treat moderate‑to‑severe persistent asthma, along with several monoclonal antibodies and an immunosuppressant. Xolair is produced from genetically modified mammalian cells that are cultivated in the laboratory before fermentation in multiple bioreactors.

Effective control is essential for a process that spans three production levels and is geographically dispersed. Novartis adopted a distributed architecture based on Emerson’s DeltaV system, allowing operator stations to be positioned close to key equipment such as bioreactors and tanks. To further enhance operator efficiency, the company designed a fully mobile control architecture.

Novartis has been a pioneer in wireless technology, first implementing it in 2000. In 2008, during its upgrade to DeltaV version 9, the company leveraged built‑in Wi‑Fi and wireless security features. The following year, the wireless footprint was expanded with additional access points, creating a complete mobile solution tightly coupled to the DeltaV platform.

“In 2000 we introduced wireless technology because it matched our needs. The latest DeltaV enhancements let us deploy a plant‑wide wireless solution,” says Philippe Heitz, head of engineering at Novartis.

The current network covers all three production levels using ten Wi‑Fi access points. It supports 17 mobile operator stations and 100 DeltaV controllers distributed across two independent systems: one for upstream cell cultivation and harvesting, the other for downstream purification and freezing. The systems will soon be linked via Emerson’s DeltaV ZONE, a software and hardware suite that connects two DeltaV installations.

Mobile stations are built for sterile environments (zones C and D). Each unit features a stainless‑steel enclosure that houses the CPU and is equipped with a USB‑enabled keyboard, monitor and mouse. The devices connect to the Wi‑Fi network, giving operators a portable, full‑control interface.

Operators can glide between levels while maintaining full process visibility, which has cut the number of required workstations by 50 %. Maintenance workflows have also improved: a single mobile workstation now suffices to calibrate instruments that previously required a team of two. Additionally, the wireless architecture eliminates the need to halt a process for workstation repairs; mobile stations can be swapped out instantly, providing a seamless backup system. When a new product launch or recipe change occurs, the mobile stations can be redeployed throughout the plant, obviating the need to install new control points.

“Because of the wireless network, we no longer need to invest systematically in new control stations, even when new products alter plant equipment or layout,” notes Patrick Boschert, automation expert at Novartis.

The synergy of DeltaV and wireless architecture has enabled Novartis to diversify its production portfolio. From a single‑chain product such as Xolair, the plant can now manufacture multi‑chain monoclonal antibodies and immunosuppressives, better serving patient needs.

About Emerson Process Management
Emerson Process Management, a division of Emerson, is a global leader in automating production, processing and distribution across chemical, oil & gas, refining, pulp & paper, power, water & wastewater treatment, metals & mining, food & beverage, pharmaceutical and other sectors. The company blends advanced products and technology with industry‑specific engineering, consulting, project management and maintenance services. Its brands include PlantWeb, Syncade, Fisher, Micro Motion, Rosemount, Daniel, DeltaV, Ovation and AMS Suite.