Smart MCC Upgrade — API Production Block Modernisation

Overview

Elezon delivered a complete Smart MCC upgrade across API production facility for a leading pharmaceutical company — modernising motor control, enhancing power reliability and enabling digital supervision across critical production utilities, solvent transfer and process areas.

The scope covered 5 intelligent MCC panels with 180+ Ethernet-enabled starters across V-Block and S-Block, engineered to pharma hazard-zone compliance standards and designed for future block expansions.

Client challenges

Prior to implementation, the facility faced several maintenance-related issues:

• Legacy MCC infrastructure with limited diagnostics and no digital supervision

• Multi-block execution across V-Block and S-Block with different process profiles

• Hazard-zone compliance for solvent transfer and API high-potency process areas

• Requirement for standardised layout to support future block expansions

• Zero tolerance for unplanned downtime during upgrade and commissioningUnexpected equipment breakdowns impacting production schedules

Objectives

The main goals of the project were to:

• Modernise motor control across all critical production utilities and process areas

• Enable real-time digital supervision via PLC and SCADA backbone

• Achieve 50kA fault withstand with full IP54 and FRLS compliance throughout

• Standardise panel architecture across V-Block and S-Block for future scalability

• Complete FAT, site support and full documentation handoverShift from reactive to predictive maintenance practices

Solution approach

Elezon designed and delivered 5 intelligent MCC panels with Ethernet-enabled feeders across V-Block and S-Block — each panel engineered to pharma-grade compliance with aluminium busbars, FRLS wiring and IP54 protection throughout. The solution unified both production blocks under a single PLC and SCADA backbone — enabling remote monitoring, motor diagnostics, MFM metering and thermal alarm management from a single supervision platform.

Key elements of the solution included:

• 5 intelligent MCC panels — IP54, FRLS wiring, aluminium busbars

• 50kA fault withstand throughout

• 180+ Ethernet-enabled smart starters

• DOL, Star-Delta and VFD integration across all process drives

• Door-interlocked isolators and arc-safety features

• Fire suppression interface, door limit and magnet switches

• Motor protection, thermal alarms and MFM metering with RS-485 integration

• Remote monitoring and diagnostics via PLC/SCADA backbone

• Standardised layout for future block expansion

• FAT + complete documentation: GA, QAP, test certificatesContinuous data collection for vibration, temperature, and load

Implementation process

The project was delivered through a structured and scalable process:

• Design & Detailed Engineering
  Process audit across V-Block and S-Block. Motor schedules reviewed. Standardised panel architecture developed for both blocks under unified design.

• Manufacturing
  All 5 iMCC panels manufactured at Elezon's Bengaluru facility. QAP compliance throughout. FAT with PLC simulation before dispatch.

• Site Commissioning
  Multi-panel execution managed across V-Block and S-Block simultaneously. Elezon's field team handled installation, termination, loop checking and PLC/SCADA integration with zero production disruption.

• Handover
  Complete documentation package — GA drawings, QAP, test certificates, wiring schedules, as-built drawings.

Conclusion

Elezon delivered a complete Smart MCC modernisation across API production facility — 5 intelligent panels, 180+ smart starters, unified PLC/SCADA supervision and full pharma-grade compliance across V-Block and S-Block. The standardised panel architecture gives the client a scalable foundation for future block expansions without re-engineering — and remote diagnostics that transform maintenance from reactive to predictive.