zenon OpenDCS – the gamechanger for process automation
The zenon OpenDCS solution represents a new generation of open process control systems tailored for the pharmaceutical, life sciences and process industries. This software-defined, hardware-independent, flexible, and scalable solution enables easy orchestration of field equipment.
zenon OpenDCS cannot be directly compared one-to-one with a traditional DCS, as these systems typically bundle both hardware and software from a single supplier. In contrast, zenon OpenDCS provides only the software component, which can run on a wide range of hardware platforms – including virtualized – free from vendor lock-in. This makes it a hardware-agnostic DCS or DCS without hardware dependency. We offer a new generation DCS based on software-defined automation and engineering principles – for faster time to market and compliant production.
zenon OpenDCS facilitates software-based, open, and modular process automation – powered by the efficiency and intelligence of Automated Engineering. In comparison to a classic DCS system, where hardware and software are closely linked to each other and specified and developed by a specific vendor, with zenon OpenDCS you gain much more flexibility and freedom.
Comparison: Classic DCS system vs. zenon OpenDCS
| Feature/Aspect | Classic DCS | zenon OpenDCS |
|
Architecture |
Hardware-centric, hierarchical |
Software-centric, modular, flexible |
|
Integration |
Tight coupling of hardware/software, proprietary |
Open, interoperable, vendor-agnostic |
|
Scalability |
Limited, hardware-bound |
High, software-driven, easily scalable |
|
Adaptability |
Slow, requires hardware changes |
Rapid, via software updates/configuration |
|
Data Handling |
Data silos, limited IT/OT integration |
Real-time, unified data flow, IT/OT fusion |
|
Lifecycle |
Long, slow to update |
Agile, supports continuous improvement |
|
Vendor Lock-In |
High |
Low |
|
Engineering |
Custom engineering per system |
Reusable software components, |
|
Cost Structure |
High upfront hardware, long maintenance |
Lower hardware dependency, flexible costs |
With a hardware-agnostic, customizable, and modular architecture, OpenDCS delivers a powerful process control system built on open standards, such as the
- MTP standard,
- OPC-UA
- ISA-88
- Profinet
- And more than 300 native protocols
Use your preferred controllers and use only one software. This includes support for containerized IEC 61131-3 compliant runtime environments, enabling even greater flexibility and reduced hardware dependency. It allows companies in the pharmaceutical and life sciences sector to design their plants to be highly adaptable and futureproof, while also facilitating seamless integration of modular systems – for example, using the Module Type Package (MTP) standard. The zenon MTP Suite enables efficient modular production by integrating existing equipment into modern automation systems. Features include real-time compliance checks, process orchestration via drag-and-drop interfaces, and compatibility with legacy equipment through MTP Gateways. This also makes it possible to integrate legacy DCS equipment and systems via zenon.
To achieve this, zenon OpenDCS has been developed as a new type of industrial control system. It is a contrast to a “classic” DCS solution consisting of hardware and software as a bundle.
-
An open architecture provides flexible options to easily integrate equipment with OpenDCS.
Transform your operations with zenon
zenon software platform was developed to ensure product safety, compliance with regulations and standards as well as quality.
Distributed Control Systems remain integral to industrial automation by offering reliability and process optimization. However, challenges such as high costs, complexity, and limited openness demand innovative solutions. Trends such as Industry 4.0, IIoT, modular production, and software-defined automation are shaping the future of this field. These trends underline the necessity of new systems in the pharmaceutical industry, such as hardware-agnostic DCS systems. zenon OpenDCS shows how advanced software solutions can address these challenges while enabling modular production and software-defined automation – accelerating progress on the path of digital transformation. By leveraging such technologies, manufacturers can achieve greater efficiency, adaptability, and sustainability in an increasingly competitive landscape.
