What is IoT and its Applications in the pharma industry?

 What is the Internet of Things - IoT

The Internet of Things refers to a network of smart devices that can collect and share data. These devices are in addition to computing devices that can perform process measurement on their own.While a main controller is required to run and  operate the entire system, IoT devices can communicate and share data themselves, without the need for a centralized controller. This is in contrast to traditional devices & sensors, that rely on a main controller to sense, transmit and process the required variable.

Like other industries, the pharma industry is also experiencing the benefits of IoT in a number of areas and departments. Its more practical application is real-time monitoring, data collection and integration with other systems for process & product improvement

The potential of IoT is enabling the pharma industry to increase its productivity, improve its compliance and enhance process monitoring for fault detection and remediation by integrating with the production process and gain valuable insights, which is lacking in the traditional system.

The IoT consists of the following components for its implementation.

● Smart devices and sensors - they are used to collect relevant data and send them to the central controller. For example, temperature, humidity and weighing

● Connectivity - it is used to provide connectivity between smart sensors and centralized controllers. For example, WiFi and Cellular network

● Centralized storage or cloud - it stores data collected by the smart sensors and the software algorithms that are applied to the collected data.

● Software — a combination of different coding algorithm that performs the desired function on collected data. It also performs record-keeping processes.

Role of IoT in the Pharmaceutical Industry

Let's briefly discuss the role of IoT in the pharmaceutical industry.

IIoT

IIoT, or Industrial Internet of Things, is a system where smart industrial devices such as sensors and actuators are interconnected to collect various process data such as temperature and humidity. The data is sent to a centralized controller for analysis, which is then used for various purposes and decision-making.

In the pharmaceutical industry, the IIoT can be deployed in various manufacturing processes, such as cleaning and filling, to monitor critical production data. A centralized computer or controller can then analyze this data for pharmaceutical-specific parameters. The outcome is fed to various digitalization tools for decision-making purposes.

For example, integrating IIoT with the packaging process allows us to collect product quality and productivity data, such as temperature, machine speed, and total output. The result is then gauged against specific metrics to determine product efficacy and quality.

Record collection and keeping

One capability of IoT is its ability to save measured values in its system, which can then be made part of related records. Integrating smart sensors with machinery & process  allows for the collection of every desired parameter, which solves common traditional record keeping problems, such as human faults, missing entries and error in reading values.

For example, area temperature and humidity are critical environmental values that must be maintained at acceptable levels and recorded. IoT technology automatically  applies the collected  data into software analytics and arrange values in the desired  record form.

Real-time data capability

Another aspect of IoT in pharma is collecting and monitoring data in real-time for various processes. By combining smart devices, relevant data processing, and data analytics, one can analyze the data coming from these sensors in a real time manner.

The data is then used for further processing, such as analyzing  underlying processes and making decisions for optimum performance.

The real- time capability of IoT can be used  in the following ways.

Predictive Maintenance - Smart sensors installed on different parts of pharma machines, measure and send machine health data, which can then be analyzed to predict machine failure or breakdown. The maintenance personnel can use this data to perform maintenance on that particular machine part before it malfunctions, and the entire machine stops . This type of maintenance is called predictive maintenance, which is largely enabled by using IoT.

Product & Process Quality—IoT can be used to monitor product quality specific parameters , such as granule size and pH value. Monitoring these granular levels variables  enables  personnel to identify product quality issues and adjust them accordingly.

Environmental parameters—Environment control in the pharma industry is critical,  and is  required for both product and compliance requirements. The IoT enables this by monitoring environmental parameters such as temperature, humidity, and air purity levels. Continuous monitoring and analysis enable it to detect abnormal values and adjust them to acceptable levels.

IoT in the pharma industry processes and applications

Now we have discussed the introduction of IoT and its role, let's dive into the applications of IoT in the pharma industry.

Optimizing pharma production processes

Manufacturing operations in the pharma industry is the core area that impacts all functions, such as cost, order fulfilment, market forecast and finance. An optimized pharma manufacturing operation is necessary for the success of other functions of the pharma business.

Traditional and manual monitoring techniques become cumbersome and difficult to handle. Additionally, personnel and management also face difficulty in using the data and converting it into useful insight.

IoT allows the pharma industry to monitor all relevant data and analyze it according to specific acceptance criteria. The results can then be used to optimize the manufacturing process, by reducing downtime, wastage and making effective production plans.  It enables personnel to analyze the production process and keep track of product parameters and equipment performance.

Documentation and records

Documentation and records are an integral requirement for the pharmaceutical industry and are specifically reviewed by the regulatory bodies. Any pharmaceutical organization is expected to maintain accurate and up-to-date documentation for every process.

IoT enables the pharmaceutical industry to accurately record all data and parameters related to every pharma process. The data sent to a centralized controller or commuting device is  capable of recording all the parameters against their specific processes. The software analytics or algorithm can be programmed to adjust these parameters into appropriate record forms that can be later used in accordance with regulatory directives.

Supply Chain

Supply chain in the pharma industry has its unique challenges due to the complexity of pharma product requirements. For example, temperature-sensitive products require specialized containers and logistics that maintain the required temperature until the product is delivered to its end user. Similarly, counterfeit products, material availability and demand forecast are some of the additional challenges for the pharma goods, that impacts the overall market condition of a pharma drug manufacturer

IoT can help overcome challenges related to the pharma supply chain. Deploying IoT devices at different stages of the supply chain allows for visibility throughout the chain. These devices can provide insightful data, such as location, current storage , logistics conditions, and  product parameters, which can then be used to effectively coordinate the supply chain.

The insightful data obtained through IoT technology can be used to solve many problems being faced by  the pharmaceutical supply chain, and could be used to optimize inventory management, logistics arrangement &  monitoring, and demand forecasting.

Clinical Trials

Clinical trials are part of the drug development process, where newly developed drug compounds are tested for efficacy. One segment in clinical trials is  monitoring patients for drug evaluations. Traditional practice has been patients or participants visiting the research centers for data collection and monitoring health status.

With the IoT, patients or participants can be monitored using smart devices  and monitor human health conditions. This allows remote monitoring of patients or participants through software and analytics to make decisions. Due to this technology, patients no longer need to visit research centres, allowing researchers to include more people in trials.

Personalized Medicines

The traditional drug focus has been product-centric, i.e. products are manufactured with standard  specifications, and patients have to adjust the dosage according to their requirement.

A patient centric approach is where every patient gets the type of drug he or she needs, and these medicines are commonly known as personalized medicines. .

IoT is one of many enablers of personalized medicines, where smart devices are used to gather patients' specific health conditions, and can also detect and communicate any side effects. This data along with other types can be used to adjust dosage quantity. It also enables mutual understanding between patients and health providers for better personalized medicines development.

Inventory Management

Inventory management is the process of managing relevant materials' inventory in a cost-efficient way to fulfill  process and market requirements. Efficient inventory management is necessary to effectively manage production planning, market forecasting, and order fulfillment.

The traditional system involves manual records, such as bin cards, to track items in an inventory. Follow-up also involves manual techniques, and there is no procedure to automatically expedite short or urgent items.

Using IoT, drug manufacturers can perform inventory management in an automated way. Smart devices, such as RFID can track each stage of an item and automatically update the record.  It can also perform automated replenishment of stocks by utilizing relevant devices and analytics.  

Some other ways IoT can be used in inventory management include the following.

● IoT devices can measure environmental parameters in storage areas. Because, like manufacturing , storage areas also require controlled temperatures to protect the drug

● IoT can be used to optimize delivery routes  considering different factors, such as weather conditions and urgency.

● Arranging items inside the warehouse or storage area for easy tracking in times of requirement