Stable, traceable processes
In the pharmaceutical and medical technology industries, a stable power supply and accurate data are indispensable. Even minor power disturbances can affect sensitive processes or jeopardize entire batches.
Janitza continuously monitors power quality, detects disturbances early, and documents events completely in an audit-ready manner—from laboratories and cleanrooms to production facilities. Power quality, energy consumption, and batch context are consolidated into a consistent data foundation so that energy and PQ events can be clearly linked to a batch.
The result: faster root-cause analyses, fewer downtimes, and a reliable basis for quality, compliance, and validations. As a globally scalable monitoring concept, Janitza also enables an efficient rollout across all sites, comparable KPIs, and early detection of anomalies.
Challenges
Pharmaceutical manufacturing places the highest demands on stability, power quality, and data integrity. Any deviation—whether caused by voltage sags, load peaks, or faulty measurement data—can impact product quality, validation, batch release, and supply reliability.
for continuous production and laboratory processes
to prevent voltage sags and disruptions to sensitive processes
of energy and process data – including batch reference (batch-to-energy correlation)
clear timestamps, event history, and role- and rights-based access concepts
such as GMP, FDA 21 CFR Part 11, EU Annex 11, and ISO 50001
for HVAC, cooling, ventilation, and cleanroom systems in 24/7 operation
for global energy monitoring and early detection of deviations
through transparent consumption data and CO2 reporting
Global energy monitoring in the pharmaceutical industry
A global company in the pharmaceutical and healthcare products sector needed a scalable solution to monitor energy consumption, grid quality, and supply risks worldwide in a consistent way – with minimal effort at plant level and audit-ready data to meet regulatory requirements.
Current situation
The pharmaceutical company was looking for a scalable solution to make energy consumption and grid quality transparent across all production sites. The goal was to implement targeted energy-efficiency measures, reduce CO2 emissions, and meet regulatory requirements such as ISO 50001, GMP, and the FDA. At the same time, voltage sags and grid disturbances needed to be detected early to avoid unplanned downtime and batch risks. A consistent data and KPI logic was especially important for results to be comparable across sites.
Solution
By introducing Janitza measuring devices (e.g., UMG 801) and the GridVis® software, an end-to-end monitoring structure was established – from capturing energy consumption to high-resolution analysis of power quality.
Thanks to standardized data models and measurement-point definitions, the relevant energy and power-quality data were available in real time and in a uniform format. This made it possible to develop cross-site KPIs and consistent reporting for the first time.
Result
The company benefits from significantly greater real-time transparency into consumption and grid quality, standards-compliant documentation of energy events, and a robust data foundation for efficiency and sustainability initiatives. The global rollout was simplified: sites can be onboarded faster, KPIs are comparable, and deviations can be detected earlier and addressed more precisely – up to and including support for root-cause analysis of disturbances that affect ongoing processes.
Power quality as a success factor in the pharmaceutical industry
Power quality is critical
Cleanrooms, constant temperature, and humidity control require 24/7 operation of ventilation, cooling, and filtration systems. These systems alone can account for up to 70% of a facility’s total energy consumption.
Continuous operation:
Production and laboratory processes run around the clock, often with high electrical loads from pumps, mixers, sterilization units, or bioreactors.
Validation and safety requirements:
Systems can rarely be shut down, as every restart requires renewed validation or risk assessment — making uninterrupted operation essential.
Power quality is critical: voltage sags, surges, transients, or harmonics can affect sensitive loads, trigger transfers, and increase batch risks—even when UPS and backup systems work reliably. In practice, a critical question often remains unanswered: What was the cause—an external utility disturbance, a switching operation, or an internal load peak?
Janitza makes this cause-and-effect chain visible. With high-resolution power-quality monitoring, power quality events are detected precisely, time-stamped unambiguously, and documented without gaps. This makes it possible to understand which disturbance triggered the transfer to UPS/backup, which loads were affected, and how the event fits into the timeline of ongoing processes.
Value: instead of reacting only to transfer events, root causes can be identified and measures derived – resulting in more stable processes, fewer unplanned interruptions, and a robust data basis for audit trails, validations, and continuous improvement.
Batch-to-Energy Correlation – Evidence, not speculation
When deviations occur during a batch, a clear correlation of grid events, load profiles, and process timestamps is what matters. Janitza provides a high-resolution event and trend history that can be integrated into batch reports. This shortens root-cause analysis and makes restart/release processes more predictable.
Risks and Costs of Unplanned Production Downtime
- Stillstandskosten je nach Produktionslinie zwischen 50.000 und über 500.000 € pro Stunde
- Materialverlusten im sechs- bis siebenstelligen Bereich, wenn begonnene Chargen durch Änderungen in Temperatur, Druck oder Reinraumbedingungen nicht mehr verwendbar sind
- Neuvalidierung oder -qualifizierung von Anlagen und Prozessen nach einem ungeplanten Stopp
- Höheres Risiko für Lieferverzögerungen und Vertragsstrafen
Secure, audit-ready power supply
as a scalable monitoring concept with Janitza
Continuous monitoring of voltage quality
for high-availability systems
Batch process monitoring
Complete monitoring and audit-ready documentation of all energy- and quality-relevant parameters—including an event timeline per batch.
Scalable measurement technology
for faster global rollouts
Standard-compliant data processing and archiving
Central transparency down to batch/line level
to provide evidence during deviations and support better process decisions
Less operational effort
through standardized dashboards, clear escalation paths, and standardized reports
FURTHER INFORMATION
Brief information Pharmaceutical Industry
The short brochure for the pharmaceutical and medical device industry gives you an insight into the topic.
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