Perrigo 2

Plant-Wide Control System Re-Commissioning

Over two hundred fifty (250) controllers have been re-commissioned without interruption to operations.

Challenge

Perrigo (formerly Wyeth Nutritionals) needed to verify the time and date functionality of the process, packaging and warehouse control systems associated with a 400,000 sf. FDA regulated facility dedicated to the manufacture of infant formula. Hallam-ICS was hired as the Commissioning Authority to re-commission all control systems in this operating facility.

Solution

Working with Wyeth, Hallam-ICS developed a Commissioning Plan and test strategy designed to avoid disruption to the Plant’s operations. We researched the systems to understand their function, then hired and managed the system vendors, working with them to develop the functional test protocols using Owner furnished templates.

Throughout the testing period, Hallam-ICS maintained test and test status schedules, oversaw test activities and documentation practices and prepared deficiency reports. Monthly project status reports were written and distributed to the project team. The executed test documents were included as part of a final commissioning report. At project conclusion, over two hundred fifty (250) controllers have been re-commissioned. All testing was completed without interruption to operations.

Results

Our team accomplished the following:

  • Successfully re-commissioned over 250 controllers in a 400,000 sq. ft. FDA-regulated facility without disrupting operations.
  • Developed a detailed Commissioning Plan and test strategy, managing system vendors to ensure thorough functional testing.
  • Delivered a comprehensive final commissioning report, including executed test documents, deficiency resolutions, and monthly status updates to keep the project team aligned.