OPC UA Interface – Standardized Communication for Industrial Systems
Last updated: 05 February 2026
The barrier-free connection between machine and system is known as OPC UA (Open Platform Communication – Unified Architecture). Its technology was introduced by the OPC Foundation in 2006 and replaced the classic, COM/DCOM-based OPC in the industrial sector. The decisive advantage lies in its platform independence: It is a unified language that every machine and every IT system (whether Windows, Linux, or RTOS) understands, regardless of the manufacturer or operating system.
How it works
The functional principle of open platform communication is based on a server-client model. In this setup, the OPC UA server in Rommelag systems is integrated directly into the control level (PLC) of the filling machine and provides the data in a structured format. During runtime, the OPC UA clients connect to the server to read previously defined data points or write new control commands.
Versatile Advantages of OPC UA
OPC UA has since become the norm in the industrial sector. In addition to the barrier-free functionality of the interface, the encrypted system impresses with the reliable securing of data. Particularly in a data-sensitive area like the pharmaceutical industry, complete protection against manipulation is indispensable. The standard provides the following mechanisms for this:
- Access permissions & authentication processes
- SSL data encryption & digital certificates (X.509)
- Data Integrity: Ensuring ALCOA+ principles through seamless audit trails, which is essential for validation according to IQ/OQ/PQ.
With the invention of the OPC UA interface, the focus was on the future: The communication technology was developed for machines and systems that do not even exist yet. For the connection of older legacy systems, gateway solutions or retrofit kits are also available to bridge the gap to the modern standard.
However, the high complexity of implementation remains a challenge. Expertise in network configuration is essential, as the later return on investment through process optimization significantly outweighs the initial costs.
Use in the Pharmaceutical Industry
Platform-independent solutions enable seamless integration of filling systems, inspection systems, and packaging guidelines into SCADA and MES systems in highly regulated pharmaceutical production.
In the context of modern aseptics, OPC UA provides the necessary real-time data for a comprehensive Contamination Control Strategy (CCS). Through the seamless transmission of process parameters – for example, from the critical filling zone of a Blow-Fill-Seal system – compliance with Grade A conditions (UDAF – Unidirectional Airflow) according to the strict requirements of EU-GMP Annex 1 is not only controlled but also documented in a tamper-proof manner.
Importance for Packaging Systems
The communication standard allows for optimization potentials and disruptive factors to be made visible early on. The use of companion specifications ensures uniform status models. This is particularly relevant for quality assurance: For example, data from Automated Optical Inspection (AOI) flows directly into the batch protocol. Since a 100% inspection for particles or defects is mandatory for parenteral drugs, OPC UA enables the efficient management of these test results.
Regarding compliance requirements (e.g., FDA 21 CFR Part 11), OPC UA offers the necessary security mechanisms for electronic signatures and records. Every change is provided with a timestamp and is traceable at all times.
Practical Questions
In practice, modeling (including namespaces), mapping according to ISA-88 and ISA-95, as well as monitoring play an essential role. The individual practical steps store data in the correct location and label it accurately. With the help of mapping, the entire process is reliably translated and categorized.
Cross-industry Relevance of OPC UA
In addition to the pharmaceutical and packaging industries, OPC UA is also the gold standard in mechanical engineering, energy technology, and the process industry. Companies worldwide benefit from the freedom to allow systems from different manufacturers to communicate with each other without barriers – both within their own operations and across company boundaries.