Developing Reliable Remote Management Capabilities for Globally Distributed Production Modules
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The Challenge
The Company had already established themselves as a manufacturer of high-quality HOCl with a line of products for multiple applications. Production required a chemist to constantly monitor the production and testing process manually to ensure the product met stringent specifications. The Company had a vision of changing the production model to support manufacture near the point of use, rather than shipping the product around the world. They were also interested in improving the sustainability of the production process by using nearby local resources instead of higher cost imported manufacturing components.
Meeting this challenge required overcoming several obstacles. First, it required a stand-alone automated manufacturing cell capable of meeting the high-quality standards required for medical-grade liquid disinfectants without constant monitoring and input from a chemist. Second, the size of the production module needed to be much smaller so it could be easily transported to a variety of global locations which the current production module (the size of a shipping container) couldn’t. The third requirement was to be able to remotely monitor the production in multiple distributed locations around the world from a centralized location, controlling product quality and capturing the data needed to verify the manufacturing process met regulatory requirements. The final requirement was to protect the intellectual property of the device from reverse engineering which was complicated since the manufacturing systems were deployed in multiple locations worldwide.
Meeting this challenge required overcoming several obstacles. First, it required a stand-alone automated manufacturing cell capable of meeting the high-quality standards required for medical-grade liquid disinfectants without constant monitoring and input from a chemist. Second, the size of the production module needed to be much smaller so it could be easily transported to a variety of global locations which the current production module (the size of a shipping container) couldn’t. The third requirement was to be able to remotely monitor the production in multiple distributed locations around the world from a centralized location, controlling product quality and capturing the data needed to verify the manufacturing process met regulatory requirements. The final requirement was to protect the intellectual property of the device from reverse engineering which was complicated since the manufacturing systems were deployed in multiple locations worldwide.
The Solution
“We have countries around the world in the queue to get our machines. There’s no shortage of need…We’re really looking to elevate to a humanitarian product in the future and S5 Solutions will definitely help in that.” |
Automation
The first step in supporting remote manufacturing was to fully automate the process so that an embedded controller could make a product of consistent quality without the need for a highly trained human operator. This was achieved with a Linux-based embedded controller. Sensors monitor the product through the stages of production. The system controls the fluid flow to mix and process the product from the raw materials into the final product, balancing the process to ensure the product chemistry meets stringent specifications. Kiosk size also had to be considered since the manufacturing devices would need to be rapidly deployed around the world to meet demand caused by the COVID-19 pandemic. |
Remote Monitoring
Remote monitoring was important for ensuring product quality at the remote production locations. Keeping that connection secure was paramount. Remote access was achieved with the use of a secure cloud and VPN to each of the production machines. This allowed local monitoring of the manufacturing cell at each remote facility. Additionally, it allowed the Company remote access to all distributed manufacturing machines, tracking production and quality in real time around the world. The data capture infrastructure was critical to demonstrate that the products and the manufacturing process meet the strict regulatory requirements for medical-grade disinfectants.
Intellectual Property Protection
Protecting intellectual property is a challenge for any proprietary process. That becomes even more challenging when that process is automated and placed in a manufacturing kiosk deployed at manufacturing sites not under direct control of the company. The machine must control the manufacturing process, using the proprietary technology and process, but must be resistant to reverse engineering.
Intellectual property protection was achieved through a combination of techniques, including VPN, real-time monitoring, cabinet intrusion detection, encryption, and cloud synchronization. The control software resides in a secure cloud, so no proprietary software on the machine is accessible.
Remote monitoring was important for ensuring product quality at the remote production locations. Keeping that connection secure was paramount. Remote access was achieved with the use of a secure cloud and VPN to each of the production machines. This allowed local monitoring of the manufacturing cell at each remote facility. Additionally, it allowed the Company remote access to all distributed manufacturing machines, tracking production and quality in real time around the world. The data capture infrastructure was critical to demonstrate that the products and the manufacturing process meet the strict regulatory requirements for medical-grade disinfectants.
Intellectual Property Protection
Protecting intellectual property is a challenge for any proprietary process. That becomes even more challenging when that process is automated and placed in a manufacturing kiosk deployed at manufacturing sites not under direct control of the company. The machine must control the manufacturing process, using the proprietary technology and process, but must be resistant to reverse engineering.
Intellectual property protection was achieved through a combination of techniques, including VPN, real-time monitoring, cabinet intrusion detection, encryption, and cloud synchronization. The control software resides in a secure cloud, so no proprietary software on the machine is accessible.
The Results
Managing production distributed around the world is a challenge for any company. Manufacturing a product with a tightly controlled chemical process in a small self-contained unit is an even bigger challenge. The design created by S5 Solutions addresses those challenges and provides a secure means of managing that worldwide production system. As a result of the customized design the Company now makes their HOCl product in many different countries. Since the kiosk can be placed near the point of use it lowers the cost of production and distribution. The compact design is scalable to be able to grow with market demand and be deployed anywhere.
The Briotech Story
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Briotech has developed a proprietary process for producing HOCl of high quality with a long shelf life. Shelf stability is one of the problems in the industry, which limits distribution and practicality of use. In different concentrations, HOCl is useful for a wide range of applications. Briotech has products that range from surface cleaners to skin care products and even mouthwash. HOCl is something your body makes. It is time-tested and safe for many uses.
HOCl is a bio-mimic of what human immune cells produce to heal and fight infection. Briotech has a range of products for skin conditions and disinfecting based off this single ingredient. With FDA approval that it is effective against fighting COVID-19, the last two years have been pivotal in scaling up production. |
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The Briotech model is environmentally conscious as well. Instead of shipping liquid cleaning products around the world, since they are heavy and mostly water, their vision is to make their product around the world close to the point of use.
The sustainable business model results provides turnkey production system capable of making their product in a small portable appliance -- essentially a portable factory they call a "WHISH." Just feed it power, water, and salt, and the produces some of the purest HOCl available. The Briotech/S5 Solutions teams’ recent accomplishments aren’t the end of the story. Briotech is developing a more portable, consumer-focused product for communities in need with capabilities for clean water and power sources in addition to the WHISH existing sanitization features. “We’re really looking to elevate to a humanitarian product in the future and S5 Solutions will definitely help in that,” said JW, Director of Product Management, Briotech. S5 Solutions is proud to be a partner with innovators like Briotech and looks forward to future collaborations in improving communities around the world. |
