Food & Beverage vs Pharmaceutical Automation
Why These Two Industries Are Often Compared, and Why That’s Risky
At, Stratos Control Systems Ltd, we have noted that the food & beverage and pharmaceutical manufacturing environments are frequently grouped together due to their regulated nature, quality requirements, and reliance on automation. On the surface, both industries appear similar: controlled processes, strict procedures, and high consequences when systems fail.
However, treating them as automation equivalents is a common and costly mistake.
While both sectors require robust, reliable control systems, the drivers behind automation design, documentation, change control, and system architecture are fundamentally different. Understanding these differences is critical when designing new automation systems, upgrading legacy PLCs, or planning long-term control system strategy.
Regulatory Drivers Shape Automation from the Ground Up
Food & Beverage: Hygiene, Throughput, and Contamination Control
In food & beverage manufacturing, automation design is driven by:
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Hygiene and washdown requirements
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Contamination prevention
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High throughput and efficiency
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Traceability for quality and recalls
Automation systems must operate reliably in wet, aggressive environments, often with frequent cleaning cycles. Control hardware, wiring practices, and enclosures must withstand washdown while remaining accessible for maintenance.
Downtime in food & beverage environments primarily impacts:
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Production output
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Waste levels
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Delivery schedules
Pharmaceutical: Validation, Data Integrity, and Controlled Change
Pharmaceutical automation is driven by a different regulatory mindset. The priority is not speed, but control, traceability, and proof.
Automation systems must support:
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Validation and revalidation
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Data integrity and audit trails
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Controlled software changes
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Batch consistency and repeatability
Here, downtime risks extend beyond production loss. Poorly controlled automation changes can trigger:
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Batch rejection
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Compliance findings
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Costly remediation and revalidation
Control Panel Design: Hygienic vs Validation-Ready
Food & Beverage Control Panels
In food manufacturing environments, control panels are typically:
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Hygienic or washdown-rated
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Built with stainless steel enclosures
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Designed for ease of access and fast maintenance
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Laid out to minimise contamination risk
Panel design focuses on physical resilience and serviceability.
Pharmaceutical Control Panels
Pharmaceutical control panels prioritise:
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Clear segregation of systems
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Controlled access
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Detailed documentation
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Traceability of components
While hygiene still matters, documentation, change control, and audit readiness are equally critical design considerations.
PLC Software Architecture: Speed vs Structure
PLC Programming in Food & Beverage
PLC software in food & beverage environments is typically optimised for:
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Fast recovery from faults
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High throughput
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Simple operator interaction
Poorly structured PLC code may still “work”, but it often leads to:
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Repeated downtime
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Maintenance dependency
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Limited scalability
PLC Programming in Pharmaceutical Manufacturing
Pharmaceutical PLC systems demand:
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Highly structured, modular code
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Clear naming and documentation
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Controlled version management
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Minimal unintended behaviour
Here, how the software is written matters as much as what it does.
SCADA & Data Requirements: Performance vs Proof
SCADA in Food & Beverage
SCADA systems in food environments typically focus on:
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Real-time visibility
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Alarm management
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Downtime tracking
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Traceability for quality
The goal is operational awareness and rapid response.
SCADA in Pharmaceutical Environments
Pharmaceutical SCADA systems must also support:
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Audit trails
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Historical batch data
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Secure user access
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Regulatory reporting
SCADA becomes part of the compliance framework, not just an operational tool.
Upgrade & Modernisation Strategy: Downtime vs Compliance Risk
Upgrading Food & Beverage Automation
Food & beverage upgrades typically prioritise:
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Minimising downtime
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Improving reliability
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Replacing obsolete PLC hardware
Phased upgrades are often driven by production constraints.
Upgrading Pharmaceutical Automation
Pharmaceutical upgrades require:
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Validation-aware planning
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Controlled testing and commissioning
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Careful change management
A technically “simple” PLC upgrade can become complex if compliance is not considered.
Common Mistakes When Automation Is Not Industry-Specific
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Applying food-grade panel design to pharmaceutical environments without sufficient documentation
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Treating pharmaceutical PLC upgrades like standard production systems
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Underestimating the compliance impact of software changes
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Failing to plan upgrades around regulatory requirements
These mistakes increase risk, cost, and downtime.
How Stratos Control Systems Supports Both Industries
Stratos Control Systems understands that regulated does not mean identical.
We deliver:
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Standards-based control panel design
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Structured PLC and SCADA systems
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Industry-appropriate documentation
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Risk-managed upgrade strategies
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Automation designed for long-term support
Our approach adapts to regulatory reality, not assumptions.
Which Automation Approach Is Right for Your Operation?
Choosing the right automation strategy depends on:
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Regulatory exposure
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Production risk
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Asset lifecycle
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Compliance obligations
Understanding the differences between food & beverage and pharmaceutical automation is the first step to reducing risk and improving reliability.
Key Differences:
Discuss Automation for Regulated Manufacturing
Food and beverage and pharmaceutical automation may look similar, but the compliance and system design requirements are fundamentally different. If you are upgrading PLCs or planning your automation strategy, speak to our team to ensure your solution fits your industry, not assumptions.