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Polyamide is required across a whole range of areas, including the manufacture of clothing, shoes and automotive components. Traditionally, polyamide is synthesized from fossil fuels in petrochemical plants. Cathay is taking a completely new approach using renewable biomass, or corn to be more precise. But the process required is a complex one, due largely to the organisms used. Digitalization can open up wide-ranging opportunities in this field. "With big data, we can learn more about the laws guiding production," says Liu Xiucai, Chairman and CEO of Cathay. "The efficiency of bio-manufacturing can only be improved by integrating the whole production chain with hardware and software control, collecting, processing and analyzing data automatically, and then feeding the analysis results back to production."

Integrated solution for integrated digitalization

The digitalization solution required to make this possible comes from Siemens. Using Simatic Sipat software with Process Analytical Technology (PAT), the researchers at Cathay search microorganisms best suited to industrial production. The plant engineering software Comos enables the construction of a digital twin. The Simit simulation software is used to test and optimize the systems. The Simatic PCS 7 process control system secures stable production. The Manufacturing Execution System (MES) Simatic IT is responsible for ensuring stable production processes by sending out electronic work orders and evaluating and recording the quality. Using the XHQ operational intelligence software, Cathay can acquire information from all systems and create detailed reports and dashboards for further optimization.Siemens also provides smart sensors, process instruments as well as Low and Medium voltage (LV /MV) electrical equipment for the new plant, and supports Cathay with technical services and system integration.

Ideally placed for the future

This integrated solution provides Cathay with the benefits of real-time feedback from production, a minimized maintenance workload, simplified troubleshooting and fixing of faults, as well as automation of many of its production steps. With these advances, the factory in Wusu is setting whole new standards on many levels. Not only is it an ultra-modern production facility, it is also a trailblazer for the future of biotechnology: "Biotechnology can be used to manufacture better materials, and to work more cost effectively than the petrochemical industry, also for mass production," sums up Liu.