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Month: October 2025

Categories
case study

Transforming Life Sciences with Advanced Automation

Life Science

Transforming Life Sciences with Advanced Automation

About Customer

The client is a unique global healthcare company, setting up a complex injectable multiproduct greenfield facility at multiple locations. The facility is designed to comply with 21 CFR Part 11 regulatory requirements, ensuring quality, safety, and scalability for manufacturing critical healthcare products.

Business Challenges

The client faced several business and technical challenges while setting up the facility:

Complex injectable multiproduct facility requiring 21 CFR Part 11 compliance

Integration of 70+ equipment under S88 Batch Process Control

Time-to-market pressure without compromising quality

Requirement for scalability to support multiple product lines

High risk of system downtime, impacting productivity

Softcon’s Proposed Solution

Softcon provided an advanced automation and control solution using Rockwell Automation’s PlantPAx DCS and related technologies. The key elements included:

PlantPAx Distributed Control System with Point IO

Plantwide Device Level Ring (DLR) Network ensuring zero downtime

60-unit FactoryTalk Batch Solution for consistent process control

Redundant HMI, Alarm & Data Servers for system reliability

Redundant Historian Server & Interface Nodes for data security

Redundant OPC Server for seamless third-party integration

ThinManager Server with 25 Clients for centralized, scalable operations

Virtualization on VMware, enabling flexibility and future readiness

System Highlights

Speed to Market: Reduced project execution and engineering cycle time

System Network & Interface: High availability with zero downtime using robust DLR

Quality: Enhanced compliance and reduced batch rejection

Plant Visibility: Real-time monitoring and data access across all operations

Decision Making: Faster insights and control through centralized dashboards

Impact & Business Outcomes

Metric

Improvement

Execution Time

Reduced significantly, enabling faster time-to-market

System Downtime

Reduced by 40% through redundant systems

Batch Rejection

Reduced by 35% ensuring higher quality output

Asset Utilization

Improved by 30% with multi-product flexibility

Decision Making

50% faster through real-time insights

Compliance & Readiness

100% 21 CFR Part 11 compliant system

Future Scalability

Virtualization ensures long-term expansion capability

Conclusion

Softcon successfully delivered a 21 CFR Part 11 compliant automation system for the client’s injectable multiproduct greenfield facility. With seamless integration of 70+ systems, robust redundancy, and centralized visibility, the client achieved faster time-to-market, reduced downtime, improved quality, and ensured long-term scalability. This solution empowers the healthcare company to meet global demand, enhance compliance, and strengthen operational excellence.

Categories
case study

Digital Transformation in the Fiber Glass Industry

Production of nylon thread in a factory

Digital Transformation in the Fiber Glass Industry

The client is a leading producer in the fiber glass industry, operating at a capacity of 22,000 MTPA. With
increasing market demand, they planned to expand their production capacity to over 100,000 MTPA.

Business Challenges

The client was facing multiple business and technical challenges:

High market demand and business opportunity worth $2.1 billion (as per Lenzinger reports)

Need for faster time-to-market without compromising quality

Requirement for scalability to support multiple products

High system downtime affecting productivity

Lack of visibility and integration across systems

Need for future readiness for ERP/MES integration

Softcon's Proposed Solution

Softcon provided a comprehensive automation and control solution using Rockwell Automation's PlantPAx DCS and other technologies. The key components included:

PlantPAx Distributed Control System with Flex 5000 IO

Plantwide DLR (Device Level Ring) Network to ensure zero downtime

Controller-based Batching Solution for consistent quality

Redundant HMI Servers with Thin Clients for future scalability via ThinManager

High-level DLR with seamless third-party integration

Optimized engineering development, saving up to 50% in development time

System Highlights

Speed to Market: Engineering development time reduced by 50%

System Network: High availability with zero downtime due to robust DLR network

Quality: Batch rejection reduced by 50%

Integration: Seamless communication with third-party systems via OPC Server

Plant Visibility: Real-time data available at both plant and process level

User Interface: Centralized and intuitive system dashboard

Impact & Business Outcomes

Metric

Improvement

Execution Time

Reduced by 20%

Downtime

Reduced by 45% due to E&I improvements

Asset Utilization

Improved by 40% through multi-product flexibility

Decision Making

60% faster with real-time visibility

Raw Material Stock

Reduced by 28% due to better visibility

Future Savings

$120,000 saved by avoiding rework for ERP/MES readiness

Conclusion

Softcon successfully enabled the client to scale their operations from 22K to 100K MTPA while ensuring
quality, efficiency, and future scalability. Through a robust automation system and smart manufacturing
practices, the client is now better prepared to meet growing market demands, improve productivity, and
reduce operational costs.

Neeta Kulkarni

Head Projects

Neeta Kulkarni

HR and CSR Director, Softcon

Neeta Kulkarni is the dedicated HR and CSR Director at Softcon Systems Private Limited. With a strong passion for people and positive change, she plays a key role in building a supportive and inclusive work environment. Her efforts help employees grow, stay motivated, and feel valued.

As a leader in Corporate Social Responsibility (CSR), Neeta also ensures that Softcon contributes meaningfully to society. From community development to employee well-being, she focuses on making a lasting impact both inside and outside the organization.

Her leadership blends care, strategy, and social awareness, helping Softcon grow as a people-first and purpose-driven company.

Vinayak Hegde

Director Sales

Vinayak Hegde

Director Sales, Softcon

Vinayak is a seasoned professional with many years of experience in creating strategic roadmaps, driving corporate growth, and delivering impressive results. He has led high-performing teams and managed diverse responsibilities, significantly increasing annual revenues for multinational companies. His innovative approach has helped companies like Siemens and GE double their revenue in record time by breaking into competitive markets.

An expert in IIoT-connected enterprise solutions and product management, Vinayak is a true source of wisdom in automation, people management, and thoughtful leadership. His dedication to quality and continuous improvement consistently propels groundbreaking achievements across various industries, making him a key force in transforming business challenges into growth opportunities.

Chintamani Unde

Service Head

Chintamani Unde

Service Head, Softcon

Chintamani Unde is a seasoned leader responsible for overseeing the entire maintenance and drives repair department, bringing extensive expertise and unwavering passion to his work.

With a strong background in managing large-scale service teams and optimizing repair processes, he consistently drives operational excellence and innovation. His strategic approach has reduced service downtime, improved customer satisfaction through proactive maintenance strategies, and optimized operational costs without compromising quality.

Chintamani’s commitment to translating vision into action and his ability to lead cross-functional teams ensure that the organization upholds high standards of quality and reliability, making him essential to boosting customer happiness and overall service performance.

Umesh Kulkarni

Project Director

Umesh Kulkarni

Project Director, Softcon

Umesh Kulkarni is the Project Director and the driving force behind our smooth operations. With many years of experience, he has built a team that works together efficiently to reach clear goals.

Umesh is known for his practical approach to solving problems and improving everyday work. He focuses on turning ideas into simple, clear actions that help the company grow and succeed. His strong leadership and dedication to continuous improvement have made the company a leader in the industry.

Umesh’s hands-on style ensures that every part of the business works well, creating a culture of steady progress and success.

Mansing Beloshe

Head Projects

Mansing Beloshe

Head Projects, Softcon

Mansing Beloshe is an experienced Project Manager with a strong background in the industrial automation industry. With expertise in Process Control, Engineering, Control Systems Design, Process Automation, and Project Engineering, he has successfully led numerous projects, driving efficiency and innovation.

His strategic approach to program and project management ensures seamless execution, from planning to implementation. A graduate of Sanjween Vidhyalay, Panchgani, Mansing is committed to delivering high-quality automation solutions that enhance operational performance and reliability.

Chintamani Unde

Service Head

As a Senior Manager for Service & Repair at Softcon Systems Pvt. Ltd., Chintamani Unde contributes knowledge and a commitment to providing outstanding service solutions.

Chintamani is essential to boosting customer happiness and upholding the organization's high standards of quality because of its emphasis on streamlining repair procedures and guaranteeing operational excellence.

Vinayak Hegde

Director Sales

Vinayak Hegde is a seasoned professional with 26 years of experience in creating strategic roadmaps, accelerating corporate growth, and producing significant outcomes. He has effectively led high-achieving teams, handled a variety of activities, and overseen yearly revenues of INR 60 crores. Vinayak has been instrumental in helping Siemens and GE double their revenue in record time by using creative tactics to break into cutthroat sectors.

He is an expert in IIoT, linked enterprise solutions, and product management, and he was awarded the Best Project Award at IIM Bengaluru. He also provides automation knowledge and thought leadership. Vinayak's dedication to quality keeps propelling revolutionary achievement in a variety of sectors.

Chandrakant Kulkarni

Managing Director

Chandrakant Kulkarni

Managing Director, Softcon

Chandrakant Kulkarni holds a degree in Electrical Engineering and Management, which laid the foundation for his technical and entrepreneurial journey. His early roles in small companies helped him develop expertise in operations, marketing, and technology, ultimately paving the way for him to establish his own company within a decade.

Initially specializing in power management and process automation, his venture expanded over 22 years into IoT, motion control, and end-to-end integration. His leadership is driven by a relentless passion for innovation and solving complex challenges, creating significant value for customers and stakeholders.

With a visionary approach, Chandrakant Kulkarni continues to inspire industry transformation, setting new benchmarks in technological advancements and business excellence.