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PI System Upgrade Case Study for Pharmaceutical Manufacturing | Réalta Technologies
19 August 2025 · Réalta Technologies · 8 min read
In this insight
Industrial data
Automation
Operational performance
Introduction:
Réalta Technologies recently completed a critical PI System upgrade for a leading pharmaceutical manufacturer. The project involved replacing ageing hardware and unsupported operating systems, ensuring the client’s data infrastructure met modern performance, security, and compliance standards.
As a trusted partner and AVEVA Endorsed System Integrator, Réalta Technologies delivered a seamless transition to a fully upgraded system without data loss, enabling the client to continue operations without disruption and minimal downtime.
The Challenge
The client’s PI System servers were operating on outdated hardware and operating systems. An upgrade-in-place was not possible due to:
These constraints required a carefully designed migration strategy that balanced operational continuity, data integrity, and validation requirements.
Possible Solutions
Drawing on extensive experience in industrial data infrastructure projects, Réalta Technologies identified three potential upgrade strategies:
Option 1: Adding New Servers to the PI Collective
Pros: Minimal downtime, data available to users throughout.Cons: Requires reconfiguring and restarting all interfaces, which can be time-consuming with large systems.
Option 2: Swapping Names and IP Addresses
Pros: No interface reconfiguration required.Cons: Brief downtime while archives are offline, though buffered data is restored.
Option 3: Building a Complete Parallel System
Pros: Safest approach, full validation before go-live, allows migration from Batch to Event Frames database in a controlled environment.Cons: Requires more time, resources, and hardware.
Chosen Solution
After carefully reviewing all available upgrade paths, Réalta Technologies determined that Option 2: Swapping Names and IP Addresses was the most effective and efficient solution for this specific project.
This decision was based on our team’s in-depth understanding of both the technical requirements and the operational constraints within regulated pharmaceutical manufacturing. By applying our expertise in designing bespoke solutions, we were able to match the upgrade approach precisely to the client’s unique needs.
Several factors influenced our decision:
This tailored solution is a clear example of how Réalta Technologies leverages its deep technical expertise and industry knowledge to deliver results that are both strategically sound and operationally safe, ensuring clients can modernise their systems without compromising productivity or compliance.
Benefits of Updating the PI System
Conclusion
This PI System upgrade demonstrated Réalta Technologies’ expertise in designing and executing complex data infrastructure projects for regulated industries. By selecting the optimal migration strategy and executing it flawlessly, Réalta ensured the client could continue delivering high-quality pharmaceutical products with minimal disruption.
As an AVEVA Endorsed System Integrator, Réalta Technologies provides tailored solutions that modernise industrial data systems while safeguarding compliance, security, and operational excellence.
Need help with updating your systems? Get in touch with our team.
Phone: +353 21 243 9113
Email: sales@Realtatechnologies.com
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+353 21 243 9113
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+1 302 509 4401
Email
sales@realtatechnologies.com
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