In Pharma, a stopped line isn’t just downtime.
It’s a failed batch.

Your engineers need answers now.

Machine Analyser® connects directly to your PLC – no additional sensors required. Your data stays fully within your network with complete offline capability. It can be live in under a day with no IT project needed, delivering real breakdown data the moment your line stops so you can respond immediately and keep operations running smoothly.

Pharma downtime isn’t just a machine problem.

It’s a diagnosis, knowledge and compliance problem.

When a Pharma line stops, four things need to happen – diagnose, understand, fix and document. Most teams struggle with all four. Machine Analyser® is built for all of them. Not just the prediction bit.

Diagnose fast - with the right data

When a Pharma line goes down, Machine Analyser® surfaces the exact fault, axis, error code and preceding events from your PLC immediately. No log searching, no calls to the OEM - your engineer has everything they need to diagnose the problem before a batch is compromised.

Understand the problem and fix it

Knowing the fault code is only half the battle. Machine Analyser® gives your engineers the full context - drive history, error patterns and preceding events - all available offline, on-site, without IT involvement. With a full asset inventory including parts and firmware versions, your team can resolve it fast.

Log it, document it, prevent the next one

Every breakdown is logged automatically with full equipment data. Machine Analyser® tracks patterns across incidents so your team can spot recurring faults, update SOPs and build a clear history of equipment behaviour - useful context for any internal review or investigation.

Built for the engineers keeping pharma lines running.
React, resolve and document – all from your PLC.

Connected directly to your PLC – no sensors, no lengthy IT project, no impact on validated processes. Fully offline if required – your data stays on-site, inside your network, always. Everything your engineers, QA and stores teams need in one platform.

Phase 1 — Breakdown
React to Breakdowns

When a pharma line stops, Machine Analyser® pulls the fault, axis, error code and preceding events from your PLC instantly. No log searching – your engineer has the full picture before the batch is compromised, with every event automatically logged for your quality system.

Phase 2 — Prevention
Monitor Performance

Machine Analyser® tracks current draw, error trends and axis behaviour across your pharma lines 24/7 – through batch runs, product changeovers and validation windows. Spot what’s developing before it affects a batch or triggers a deviation.

Phase 3 — Planning
Plan Smarter 

Usage data, wear trends and a full asset inventory – parts and firmware versions included. Your maintenance teams can plan windows around scheduled shutdowns and actual machine condition, not a fixed calendar – keeping validated processes intact.

In pharma, downtime doesn’t just cost money.
It costs batches.

Industry research and the reality we see every day on the pharma factory floor.

£40K

Estimated cost per hour of unplanned downtime in manufacturing

81 min

Average incident duration – up from 49 minutes five years ago

12 hrs

Avg. unplanned stops per year in pharma manufacturing

9/10

Manufacturers want condition monitoring but most still don’t have it

From Installation to Intelligence in 3 Simple Steps.

No rip-and-replace. No lengthy IT project. No sensors to install. Read-only connection - zero impact on your validated process. Fully offline if required - your data never has to leave the building.

Connect

Plug directly into your PLC - no sensors, no hardware, no disruption. Works with ELAU PacDrive and legacy systems instantly.

Monitor

Cloud or offline - no IT sign-off. Continuous PLC data tracking. Learns patterns and flags anomalies with 24/7 coverage.

Act

Turn insights into action. Get instant alerts, predictive warnings, and plain-language tips for faster, smarter planning.

Built for the realities of pharma manufacturing.

Pharmaceutical lines have pressures no other sector faces – regulatory scrutiny, validated processes and zero tolerance for batch failures . Machine Analyser® is designed for all of it.

  • Batch Protection

    Catch developing faults before they stop a batch mid-run

    In pharma manufacturing, a mid-batch failure doesn't just stop the line - it risks the entire batch and triggers a deviation process. Machine Analyser® monitors your equipment continuously and surfaces early warning signs so your team can act during a planned window, not in the middle of a critical run.

  • Validated Environments

    Read-only data collection that never touches your validated process

    Machine Analyser® uses a read-only connection to your PLC - collecting diagnostic data without interfering with your validated manufacturing process. No changes to your control system, no impact on IQ/OQ/PQ status. And critically - it runs fully offline if needed. Your data stays on-site, inside your network, with zero external connectivity. No IT security risk, no data governance concerns, no obstacles to deployment.

  • Regulatory & Audit Trail

    A complete equipment history your quality team can actually use

    Every breakdown, fault event and preceding event is logged automatically with timestamps and error codes - giving your quality and engineering teams a complete, searchable history of equipment behaviour. This supports internal investigations, maintenance reviews and deviation reporting without any additional manual recording.

  • Scheduled Shutdowns

    Plan maintenance around your production schedule, not around failures

    Pharma lines run to strict batch schedules - emergency maintenance is never just inconvenient, it's a regulatory event. Machine Analyser® gives your team the wear data and trend reports to schedule maintenance during planned shutdowns, keeping your validated processes intact and your compliance record clean.

  • Multi-Product Lines

    Full visibility across every product changeover

    Pharmaceutical lines running multiple products face unique equipment stress at every changeover. Machine Analyser® tracks machine condition across each product run - giving your engineers and QA teams a complete picture of equipment behaviour and any deviations that occurred during each batch.

Ready to diagnose faster, resolve smarter and document everything?

No sensors. No lengthy IT project. No data leaving your network.
FULLY OFFLINE AVAILABLE. Connect to your PLC today and get your first insights before the end of the day.

 

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