Enhancing Biotech Manufacturing Efficiency Through Real-Time Asset Tracking

Asset Tracking

Asset Management

Site Visulisation

Location: Grangcastle, Ireland
Facility Type: Integrated Biotechnology Plant
Campus Size: 90-acre Biopharmaceutical Campus
Solution Delivered: December 2023
Assets Tracked: roduction, Calibration & Development Assets (750+)

PlantQuest deployed a powerful asset tracking and site visualisation platform at a biotechnology campus in Ireland, a state-of-the-art facility specialising in mammalian cell culture, vaccine production, aseptic syringe filling, and mRNA drug substance manufacturing. The project focused on enabling real-time visibility and traceability for over 750 critical assets across cleanrooms, production suites, and development areas—eliminating delays, supporting compliance, and simplifying site operations. This facility is one of four within the organisation's global network using PlantQuest’s technology—alongside a multi-product pharmaceutical plant in North America, an oral solid dose manufacturing site in Ireland, and an integrated aseptic production and packaging facility in Belgium.

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The Challenge Faced

As one of the most advanced biotechnology manufacturing sites in Europe, the Grange Castle facility faced complex challenges stemming from high-throughput production and sensitive, GMP-compliant processes. Operations were being slowed and strained by:

Asset Visibility Gaps: Critical mobile assets—including test bags, sterile tubing, peristaltic pumps, MES carts, and orbital shakers—were routinely misplaced or difficult to locate in time-sensitive cleanroom settings.
Loss of Time and Productivity: Valuable production and QC time was lost daily due to the unavailability or misplacement of shared equipment like MES carts, batch record kits, or small components (e.g., hoses, clamps, gaskets).
Audit and Compliance Pressures: Poor traceability of GMP-critical items (e.g., calibrated components, single-use assemblies, and batch records) posed a risk to audit readiness, especially in aseptic and mRNA production areas.
Departmental Silos: Different operational areas—including production, calibration, and drug development—lacked a unified system for managing and locating mobile assets, creating bottlenecks and inconsistencies.
Scalability Concerns: With an evolving product portfolio and increasing production demands, the facility needed a system that could scale with minimal IT burden and integrate with future digital and Industry 4.0 initiatives.

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The Solution

PlantQuest implemented a real-time asset mapping and visualisation solution purpose-built for high-complexity biotech manufacturing environments. The system seamlessly integrated with existing site infrastructure and cleanroom protocols while delivering:

Comprehensive Asset Visibility

Real-time location tracking and digital mapping of 750+ production and development assets across all buildings and cleanroom zones.
Equipment tracked included:
- Test Bags
- Terumo sterile tubing kits
- Peristaltic Pumps
- Orbital Shakers
- MES Carts
- Batch Records and Documentation Kits
- Hoses and small components critical for cleanroom production
- Other miscellaneous production equipment

Smart Navigation & Notifications

Location-aware notifications for idle or relocated assets.
Alerts for assets that remained stationary or within a geofence for select period of time, or overdue equipment returns.
Asset history logs to track movement between cleanrooms and suites for audit traceability.

Role-Based Interfaces for Every Department

Production teams could instantly locate MES carts, single-use kits, and pumps during batch setups.
Quality Control and Calibration teams tracked the availability and usage of key equipment and documentation.
R&D and Pilot Plant teams ensured critical drug development tools were traceable and audit-ready.

The Outcome

The PlantQuest deployment at Grange Castle was completed within two months, including mapping, testing, and onboarding. The solution delivered tangible improvements in operations and compliance, including:

Productivity Gains & Time SavingsCost Avoidance

By eliminating misplaced or underutilised equipment, the site reduced duplicate purchasing and improved inventory accuracy.
Better visibility of reusable test bags, tubing, pumps and documentation kits prevented unnecessary replacements.

Enhanced Audit Readiness

The facility improved its compliance posture by ensuring real-time traceability of GMP-critical tools and records.
Audit prep time dropped significantly, with inspectors and QA staff now able to verify asset usage histories and current status in just minutes.

Cross-Site Integration & Future-Proofing

As one of four global sites using PlantQuest’s platform, Grange Castle now benefits from shared practices and solution alignment across the organization’s digital manufacturing ecosystem.
The deployment established a foundation for future asset intelligence integrations—such as predictive maintenance, RFID-enabled tracking, and deeper integration with MES and calibration systems.

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The PlantQuest solution at Grange Castle represents a significant leap forward in biotech manufacturing efficiency, compliance, and scalability. With critical assets visible, traceable, and audit-ready at all times, the site has dramatically improved day-to-day operations while preparing for the future of digital manufacturing.

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