In pharmaceutical and chemical production, decades-long plant lifespans clash with short-lived electronics. Outdated HMI systems jeopardise availability, audit security and cyber resilience. In this article Pepperl+Fuchs demonstrates how modular and remotely maintainable HMI concepts reimagine the life cycle and resolve typical pain points.
An operator in the pharmaceutical filling area reports a flickering HMI. The display is flickering, and inputs are not being recognised. The suspicion: a hardware defect. But instead of a quick replacement, the process involves removal, shipping and waiting. The current batch is delayed, and the production line comes to a standstill. The next audit is just around the corner.
Situations like this are an everyday occurrence in many chemical and pharmaceutical plants. They demonstrate how urgently HMI concepts are needed that meet the real-world demands of long-lasting equipment, and do not compromise availability, audits and flexibility.
Reality in the Life cycle: When Technology Ages
Production facilities in the process industry are designed to last for decades. HMIs, on the other hand, age faster—displays fade, touch screens respond sluggishly, power supplies fail. If a defect occurs, replacement often means: entering the cleanroom, completely removing the device, waiting weeks for a replacement—often a no-go when production is running simultaneously.
At the same time, changes to the HMI are always a compliance issue. In GMP-critical environments, a simple update can trigger a revalidation. Operators face a choice: take risks or postpone necessary updates. Cybersecurity, patch requirements, and new regulations such as NIS2 or the Cyber Resilience Act further exacerbate this conflict of objectives.
At the same time, production itself is changing. Smaller batches, more frequent product changes, new locations. All of this requires mobile, flexible, and remotely manageable HMI systems. Traditional “send-in-and-wait” approaches are reaching their limits.
Modularity as the Solution
The VisuNet series from Pepperl+Fuchs offers an alternative approach: modular instead of monolithic. The display, computer, and power supply are designed as separate, field-replaceable modules. This means that in the event of a failure, the entire device does not need to be removed—a targeted component replacement in the field is sufficient, even in explosion-hazardous areas up to Zone 1/21. The GMP environment remains unaffected and downtime is minimised.
The housing design is also tailored to the requirements of hygienic environments: stainless steel, smooth glass front, no crevices. The devices meet IP66 and are designed for use in cleanroom classes up to B/C. In practice, they are frequently used in Class C or D environments, where auditors pay attention to every detail.
Remote Management Without Cleanroom Access
With the VisuNet RM Shell thin client firmware and the central VisuNet Control Center tool, configuration, updates, and user management can be controlled remotely. There is no need to enter the cleanroom (a massive relief for servicing, IT and quality assurance). Updates are performed securely, and are documented and traceable, in accordance with GMP, Annex 11 and 21 CFR Part 11.
This is based on Microsoft Windows 10 IoT Enterprise LTSC, on which the VisuNet RM Shell runs. This “Long Term Servicing Channel” guarantees up to ten years of security support, without automatic functional changes or mandatory feature updates. For operators, this means: predictable servicing, long-term operational reliability and audit compliance throughout the entire life cycle.
Security features are also integrated: multi-factor login via radio frequency identification (RFID), role-based user management, and seamless audit trails ensure transparency. This means VisuNet HMIs remain on the safe side even in light of new cyber regulations, providing operators with greater control over the entire life cycle of their systems.
Flexibility and Security for Decades
The demands on HMIs in the process industry are increasing. Plants operate for decade; systems installed today must still be updatable, maintainable and audit-compliant tomorrow. Pepperl+Fuchs meets this challenge with modular, remotely manageable solutions that take the life cycle into account rather than hinder it.
Partnership with Körber – End-to-End Life Cycle Approach
Pepperl+Fuchs and Körber have been working together since 2025 to further optimise the technical integration of VisuNet HMIs into the PAS-X MES. The goal is smooth and reliable operation in the field, especially in validated pharmaceutical environments. VisuNet devices are already PAS-X Ready today, meaning they are technically compatible with the leading MES for the life sciences industry. Together, both partners are working to further standardise the integration: with specific configuration profiles, coordinated recommendations and system structures that can be maintained over the long term. For operators, this means greater planning reliability throughout the entire life cycle; from initial commissioning to updateable, seamless operation in digitised production.
