QB Control vs SIMATIC PCS7 Comparison

At a glance

Dimension	QB Control	SIMATIC PCS 7
Product category	SCADA-class bioprocess platform	Full DCS (Distributed Control System)
Best-fit scale	250 mL – 100+ L (lab to pilot)	◆ 200 mL – 20,000+ L (production)
Deployment model	◆ Plug-and-play, self-deployable	Requires professional integrators
Software delivery	◆ Browser-based, any OS	Windows 11 IoT / Server
Configuration	◆ Drag-and-drop + 37 pre-built services, no code	IEC 61131-3 (CFC/SFC) + ISA-88 BATCH
Deployment time	◆ Days to weeks	3 to 12 months
Vendor strategy	◆ Open (OPC-UA, Modbus, MQTT, REST, SQL)	Proprietary SIMATIC / PROFINET

Executive Summary
Platform Philosophy
Architecture & Hardware
Parallel Processing
Multi-Vendor Integration
Software Module Comparison
Services Catalog & Rapid Deployment
Recipe Engine
Regulatory Compliance
Pricing, Licensing & TCO
Industry Fit Analysis
What QB Control Can Replace
Where QB Control Creates Superior Value
Gaps & Limitations
Migration & Replacement Scenarios
Competitive Positioning Strategy
Feature-by-Feature Matrix

Appendices — Summary Scores by Category · Sources

1. Executive Summary

The Core Argument

Siemens SIMATIC PCS 7 is a full-scale DCS (Distributed Control System) designed for enterprise-level process manufacturing across pharmaceuticals, chemicals, oil & gas, and food & beverage. QB Control is a SCADA-class, browser-based platform designed specifically for modular liquid handling and bioprocessing — and deployable both on QB Edge (benchtop QB Modules) and on a standard industrial PC driving stainless-steel, PLC-based systems via OPC-UA for pilot- and production-grade installations.

These remain fundamentally different products serving overlapping but distinct markets. The comparison is most relevant in upstream bioprocessing from lab bench through pilot scale (150 mL – 50 L benchtop, and stainless-steel pilot/production via PLC), where PCS 7 is heavily over-engineered, integrator-dependent, and slow for development work, and QB Control provides a right-sized, cost-effective alternative.

Key Finding

QB Control does not replace PCS 7 in all scenarios. It replaces PCS 7 in specific, high-value segments where PCS 7’s enterprise architecture, German engineering depth, and production-scale assumptions create over-engineering, cost, and vendor lock-in friction. With the industrial-PC deployment path, that addressable footprint now extends upward into stainless-steel pilot and production cells that previously defaulted to a DCS. The sweet spot for QB Control as a PCS 7 alternative is:

Scenario	QB Control Replaces PCS 7?	Value Driver
Lab-scale bioprocessing (150 mL–10 L)	✅ Full replacement	85% cost reduction, days vs. months setup
Pilot-scale upstream (10–50 L benchtop)	✅ Full replacement	70–80% cost reduction, modular flexibility
Stainless-steel pilot/production (PLC + OPC-UA)	✅ Strong replacement (new)	Industrial-PC deployment, no DCS tax
Parallel fermentation (multi-vessel)	✅ Strong replacement	Plug-and-play parallel, no SI needed
Process development & DoE	✅ Superior alternative	Faster iteration, lower barrier to entry
Single-use bioprocessing	✅ Strong replacement	Native SU support, no legacy baggage
GMP production (>200 L, multi-train)	⚠️ Partial / complementary	QB Control for monitoring & control; PCS 7 for plant-wide orchestration
Continuous manufacturing	❌ Not a replacement	PCS 7’s APC, MPC & PAT capabilities required
Enterprise-wide multi-site DCS	❌ Not a replacement	Different product category entirely

2. Platform Philosophy

Fundamental Architecture Difference

Dimension	PCS 7	QB Control
Product Category	DCS (Distributed Control System)	SCADA-class browser-based platform
Design Philosophy	Enterprise-first, top-down	Modular-first, bottom-up
Target Scale	Plant-wide (200 mL – 20,000+ L)	Lab-to-pilot (150 mL – 50 L benchtop); stainless-steel pilot/production via PLC + OPC-UA
Approach to Hardware	Proprietary AS 410 controllers + ET 200 I/O + 3rd-party instruments	Own modular hardware (QB Modules) + open sensors; or existing PLCs (Wago/Siemens/Beckhoff)
Software Delivery	Installed on Windows workstations + Windows OS servers	Browser-based (any device, any OS)
Deployment Host	AS 410 controllers + Windows OS/historian servers	QB Edge for benchtop or standard industrial PC for PLC-based stainless steel
Configuration Model	IEC 61131-3 (CFC/SFC programming) + ISA-88 SIMATIC BATCH	Visual drag-and-drop + recipe designer (no coding)
Deployment Time	Months (engineering, commissioning, validation, SI required)	Days (plug-and-play)
Vendor Strategy	Proprietary SIMATIC ecosystem (lock-in via PROFINET/PROFIBUS)	Open ecosystem (no lock-in)
GAMP Classification	Category 5 (custom CFC/SFC code)	Category 4 (configurable software)

The Over-Engineering Problem

PCS 7 assumes the client needs enterprise-grade process control with full ISA-88 compliance, SIMATIC BATCH, advanced process control, and integration into plant-wide SCADA/MES/ERP systems. That is correct for large production facilities but heavily over-engineered for lab and pilot work — R&D and DoE teams, 10–50 L pilot cells, stainless-steel cells that have a PLC but no need for a full DCS, academic labs, CDMO campaigns, and cosmetics/food & beverage formulation. QB Control is purpose-built for these scenarios, and now scales up the stainless-steel pilot/production path through industrial-PC deployment and OPC-UA/PLC integration — without inheriting DCS cost, lock-in, or validation burden. (See §16 for the one-line positioning summary.)

3. Architecture & Hardware

Controller & Hardware Architecture

Component	PCS 7	QB Control
Central Controller / Host	AS 410 / AS 410H automation systems (proprietary Siemens hardware)	QB Edge (runs QB Control locally) or industrial PC for PLC-based stainless-steel systems
I/O Architecture	ET 200 remote I/O via PROFINET/PROFIBUS; marshalling cabinets + terminal rows	Power-over-Ethernet (one cable = power + data per module); or PLC I/O (Wago/Siemens/Beckhoff) via OPC-UA
Execution Speed	~25 ms scan cycle (SIMATIC kernel)	Real-time within PoE/PLC network latency
Max Devices Per Hub	AS 410 + ET 200 expansion (100s of channels)	7 per QB Edge, expandable via QB Switch (7+7+7…); PLC-bound for industrial-PC deployments
Device Discovery	Manual configuration via STEP 7 / TIA Portal + commissioning	Auto-discovery (Plug & Play) — device appears in QB Control automatically
Workstation Requirement	Approved-vendor PCs, Windows 11 IoT LTSC / Server 2024; per-seat CALs	Any device with a browser (Chrome, Firefox, Edge, Safari)
Form Factor	19” rack-mount AS 410H + marshalling cabinets, cable trays	Bench-top modules (310×115×115 mm each); or industrial PC + existing PLC cabinet
Power Architecture	Separate 24V DC supplies per cabinet + redundant UPS	PoE — single cable per module, no external power supplies
Wiring	Complex terminal boards, marshalling, analog/digital/power segregation	Single Ethernet cable per module — minimal wiring
Redundancy	S2 architecture, H-sync (FMR), PROFINET RT/IRT for critical paths	Single host per facility; multiple hosts can run parallel processes

QB Modules Hardware Ecosystem vs. PCS 7 + ET 200 Integration

Function	PCS 7 Approach	QB Control Approach
Pumps	3rd-party pumps via PROFIBUS/HART or analog I/O with custom CFC blocks	QB Pump (peristaltic, centrifugal, syringe) — native integration; SmartPump (OPC) for 3rd-party
Sensors	Hamilton/Mettler Toledo via PROFIBUS DCP or HART adapters (engineering per integration)	QB Multisensor — connects up to 6 Hamilton/Mettler Toledo probes natively
Agitation	3rd-party controllers via analog/PROFIBUS; custom CFC feedback loops	QB Agitator, QB Multiagitator (2 or 6 vessels) — native
Temperature	Huber/Lauda or equivalent via PROFIBUS/analog; custom CFC PID loops	QB Thermo (heating/cooling 2–42 °C, heating mats) — native
Gas Flow	Mass Flow Controllers via analog or HART	QB Gasflow (up to 2 gas streams, 0.1 SCCM – 20 SLPM) — native
Valves	3rd-party solenoid/pneumatic via discrete I/O; manually engineered state machines in CFC	QB Pinch Valve, QB Selector Valve (24 positions), three-way valves — native
Scales	Mettler Toledo/Kern via serial converters to ET 200	QB Multiscale (up to 6 scales via RS232) — native
Foam Detection	Not standard (custom sensor integration required)	QB Foam Sensor — optical, patent-pending, non-contact
Lighting	Not part of PCS 7 ecosystem	QB Light (up to 6 independent LED outputs for photobioreactors)
Pressure	3rd-party transmitters via HART/analog	QB Pressure Sensor (up to 2 single-use IBP transducers)

Key Hardware Advantage: QB Control

No marshalling cabinets, no terminal rows, no cable trays, no power distribution boards for benchtop deployments
Auto-discovery eliminates manual device commissioning in STEP 7
PoE eliminates separate 24V DC power infrastructure and UPS
Bench-top form factor — no rack room, no control cabinets
Open sensors — use Hamilton, Mettler Toledo, Levitronix at market price (no Siemens-integrator markup)
New: for stainless-steel systems with existing PLCs, QB Control deploys on an industrial PC and integrates over OPC-UA — reusing field hardware instead of replacing it

Key Hardware Advantage: PCS 7

Enterprise redundancy — S2 architecture with PROFINET RT/IRT for critical paths
Massive I/O capacity — AS 410 + ET 200 expansion accommodates 100s of control loops
Intrinsically safe areas — PROFIBUS PA for hazardous-area production
Proven at scale — thousands of deployed PCS 7 systems in pharma/chem/petrochemical plants
Plant-wide PROFINET fiber backbone — supports redundant networks for multi-building sites

4. Parallel Processing

Side-by-Side Comparison

Capability	PCS 7	QB Control
Max Parallel Bioreactors	32+ via PROFINET; configurable at production scale	Multiple parallel processes (license-dependent); QB Multiagitator supports 6 vessels per module; multi-instance services per process
Parallel Architecture	Each bioreactor = independent ISA-88 Unit Module with batch execution	Each bioreactor = independent Process with own P&ID, alarms, recipes, batch recording
Shared Resource Management	SIMATIC BATCH Executive arbitration for CIP/SIP, media prep	Process-level resource allocation via System and Process modules; conflict blockade prevents collisions
Independent Recipes Per Vessel	Yes — ISA-88 procedural model with multi-unit coordination	Yes — different recipes per process; parallel and sequential batch execution
Sequential Campaign Queuing	SIMATIC BATCH Campaign Manager	Sequential batch execution with Pending queue status + per-batch auto-stop conditions (new)
Unified Data View	SIMATIC Historian (all units → one database, SQL-queryable)	QB Graphs (per-process live + history), Reports (per-batch)
Cross-Batch Comparison	InfoBatch analytics	QB Graphs multi-parameter overlay + CSV export for external analysis
Technology Transfer	ISA-88 recipe structure enables formal lab→production handover (requires re-engineering for scale)	Process & recipe Import/Export with device mapping & conflict resolution; P&ID preserved on versioning
Campaign Management	SIMATIC BATCH Campaign Manager	Recipe Executions Board with full batch lifecycle (Pending, During Execution, Paused, Hold, Completed, Failed, Aborted)

QB Control’s Parallel Processing Model

QB Control implements parallel processing through its System → Process → Batch hierarchy:

System defines the physical resources (devices, services, equipment, media)
Multiple Processes can be defined within a system, each with its own auto-generated P&ID, alarm configuration, recipe assignment, batch recording, and reports
Multi-instance services allow the same service type to be instantiated across multiple processes
Parallel Recipe Execution — multiple recipes run simultaneously across different processes
Sequential execution (new) — batches can be queued with a Pending status and chained with auto-stop conditions, enabling unattended campaign sequencing
Process-level isolation — each process operates independently with its own control loop and its own per-process emergency stop (P-Stop)

Where QB Control Excels in Parallel Processing

No system integrator needed to set up parallel operations (PCS 7 requires Solution Partner planning and ET 200 re-commissioning)
Visual P&ID per process — auto-generated from configuration, not manually drawn in a WinCC/Visio designer; preserved and copied forward on versioning
Process & recipe Import/Export with device mapping — replicate a proven setup to new bioreactors and remap devices to the target system instantly
Multi-user concurrent access — different operators monitor/control different processes simultaneously from different devices, with no per-seat CAL penalty
Lower incremental cost — adding a parallel bioreactor = adding QB Modules + license expansion (not buying new AS 410, new ET 200 racks, or new licensed workstations)

Where PCS 7 Excels in Parallel Processing

Higher vessel count at large production scale (32+ units per network, thousands across multi-site)
More sophisticated resource arbitration (SIMATIC BATCH Executive for shared CIP/SIP and feed-tank contention)
ISA-88 full formalization with standardized terminology and structure
Batch Historian + InfoBatch for enterprise-grade production reporting
PROFINET RT/IRT synchronization across 100+ distributed units

5. Multi-Vendor Integration

Protocol Support Comparison

Protocol	PCS 7	QB Control
OPC UA	Supported via FDI / OPC UA adapters; legacy OPC DA limited to 32-bit	Native — primary path for PLC/stainless-steel integration; dedicated OPC UA Connector module with configurable mappings
Modbus	Not native (3rd-party gateways / SIMATIC NET adapters)	Supported (TCP and RTU)
MQTT	Not native (requires custom gateway / TIA Portal extension)	Native — IoT real-time streaming
REST API	Not native (WinCC custom web modules only)	Native — modern web integrations
SQL (JDBC/ODBC)	Via proprietary Historian database structures	Native — direct database access
LDAP/Active Directory	Supported via Windows OS integration	Native — SSO with corporate credentials, configurable search scope/timeout/pagination
MTP (Module Type Package)	MTP support for NAMUR modular manufacturing	Supported (new) — plug-and-produce integration + MTP-oriented signal presentation in Graphs
PROFINET / PROFIBUS	Native (AS 410 primary bus; RT/IRT, PROFIBUS DP/PA)	Profibus supported; PLC protocols (Wago/Siemens/Beckhoff)
HART	Native (via SIMATIC NET HART gateway)	Not primary (sensors via Modbus RS485)
Foundation Fieldbus	Native (but users report segment losses & complexity)	Not supported (not needed for target scale)
Bluetooth / WiFi / LTE	Not supported	Supported (QB Edge wireless options)
Serial (RS232/RS485)	Via ET 200 converter modules	Native (QB Multiscale, QB Multisensor)
SMTP (email)	Via custom gateway or WinCC	Native — notification dispatch with SMTP config + delivery logs
Secured external communication	Via DMZ/gateways	Supported — encrypted, protected external traffic

Sensor Vendor Support Comparison

Vendor	PCS 7	QB Control
Hamilton	Via HART adapters or PROFIBUS DCP integration (requires engineering)	Native — Arc module sensors via QB Multisensor (DO, pH, conductivity, OD, CO₂, ORP); two-point / zero-point / slope calibration
Mettler Toledo	Via HART adapters or Fieldbus (integration effort)	Native — ISM/Modbus sensors via QB Multisensor (DO, pH, ORP, CO₂, conductivity)
Levitronix	Custom Modbus/serial adapters required	Native — flow meters via QB Multisensor
Mettler Toledo / Kern Scales	Via analog input or serial port converters to ET 200	Native — MT-SICS / PKP series via QB Multiscale

Integration Philosophy Difference

PCS 7: “We provide the industrial automation platform; you bring 3rd-party bioreactors and instruments, and we integrate them via industrial protocols (PROFIBUS, HART, OPC-UA). Pre-engineered integrations exist for select OEM partners (Sartorius Biostat, Applikon V-Control) but still require significant engineering and Siemens Solution Partner engagement.”

QB Control: “We provide both the control platform AND the hardware modules. Our modules natively connect Hamilton, Mettler Toledo, and Levitronix sensors. For anything else, we offer OPC UA (with a dedicated connector), Modbus, MQTT, REST API, SQL, and MTP — and we deploy on your existing PLCs for stainless-steel systems. No adapters, no gateways, no system integrators needed.”

QB Control’s Integration Advantage

Native sensor support — Hamilton and Mettler Toledo probes connect directly to QB Multisensor via Modbus RS485. No HART adapters, no PROFIBUS DCP, no Foundation Fieldbus complexity
Modern protocols — MQTT, REST API, SQL are native. PCS 7 requires custom gateways for these
OPC UA Connector — a dedicated module bridges OPC-UA equipment into QB Control with configurable mappings, connector profiles, and per-connector service templates — the path for PLC-based stainless-steel systems
MTP support (new) — plug-and-produce modular integration, closing a gap PCS 7 previously held alone
Auto-discovery vs. manual STEP 7 commissioning — plug in a QB Module and it appears in the inventory automatically

PCS 7’s Integration Advantage

Pre-engineered OEM kits for Sartorius Biostat STR Gen 3 and Applikon V-Control (reduce greenfield integration time)
Mature MTP tooling (MTP Merge Utility) with a longer track record at production scale
Broader industrial protocol support for legacy plant integration (Foundation Fieldbus, PROFINET S2 redundancy, PROFIBUS PA for intrinsically safe areas)
Plant-wide integration — connects to MES (Syncade, SAP), ERP, LIMS at enterprise level
Proven at production scale with complex, multi-vendor installations

6. Software Module Comparison

Module-by-Module Mapping

QB Control ships 18 software modules, accessed through the Portal. The two additions since the previous comparison are Remote Access and Health Monitoring.

Capability Area	PCS 7 Component	QB Control Module	Comparison
Device Management	AMS Device Manager + manual PROFIBUS/PROFINET commissioning	Inventory (auto-discovery, device status, configuration import/export, licensing)	QB simpler & faster
System Configuration	STEP 7 / TIA Portal Explorer	System (visual resource allocation, search, bulk add/remove, history to CSV)	QB no-code; PCS 7 more powerful for large plants
Process Configuration	Control Studio (CFC, SFC editors) + Batch configuration	Process (visual binding, versioning, duplicate process, live connection status, guided import/export)	QB faster; PCS 7 more ISA-88 compliant
Process Visualization	WinCC (Windows-based SCADA HMI builder)	P&ID (auto-generated, drag-and-drop, recipe execution from diagram, P-Stop/E-Stop)	QB auto-generates; PCS 7 manual designer
Batch Management	SIMATIC BATCH (ISA-88 full compliance)	Recipe (Designer / Batch / Executions Boards)	QB visual designer with Services; PCS 7 more formally ISA-88
Services Catalog	No equivalent (custom CFC/SFC per project; generic APL blocks)	Services (~40 templates across 10 categories, load & execute in minutes)	QB unique advantage
Service Profiles	No equivalent (custom parameter sets)	Service Profiles (reusable grouped/atomic parameter templates, portable import/export)	QB unique advantage
Alarm Management	DCS Alarm Management (ISA-18.2)	Alarms (ISA-18.2 conformance, watchlist, in-app global notifications)	Comparable (both ISA-18.2)
Data Visualization	SIMATIC Historian + InfoBatch trending	Graphs (live + history, multi-axis, annotations, MTP signals, export)	PCS 7 more powerful historian; QB adequate for scale
Reporting	InfoBatch + Syncade MES	Reports (automated + manual, PDF/DOCX, recipe-execution & service-history sections)	PCS 7 enterprise-grade; QB sufficient for lab/pilot
Batch Tracking	SIMATIC BATCH Historian (event logging)	Runs (per-process, batch ID, user tracking, report linkage)	Both adequate
Calibration	External (AMS Device Manager)	Calibration (status tracking, Next Due Dates, Hamilton/pump methods, device-type-aware history)	QB integrated; PCS 7 external tool
Audit Trail	Event Chronicle (immutable, searchable via InfoBatch)	Audit Trail (21 CFR Part 11 conformance, cross-module, exportable CSV)	Both strong
Access Control	Windows-based user management + WinCC roles	Users & Roles (RBAC, granular per-module permissions, LDAP/AD)	QB more modern (web-based)
Notifications	Custom WinCC messaging + email gateways	Notifications (in-app center, email/SMTP, per-user preferences, recipe-step alerts, logs)	QB richer out-of-box
Backup	System backup utility (image-based)	Backup, Export & Archive (scheduled/manual wizards, one-click restore, integrity verification)	Comparable
License Management	SIMATIC License Key (hardware-locked, per-feature)	License (feature/device/system/time-based, online/offline, host-bound, license guards)	QB more flexible
Remote Access	WinCC Unified web client / Windows remote infrastructure	Remote Access (secure VPN, QR-code setup, phone/tablet/PC, role-based) — new	QB simpler, multi-device
Health Monitoring	Diagnostics across STEP 7 / WinCC tools	Health Monitoring (system health dashboard, per-module status, drill-down) — new	QB consolidated, always-on
MPC / Advanced Control	PredictPro (economic optimizer / APC)	❌ Not available	PCS 7 wins
PAT Integration	SIMATIC PAT (embedded spectral analytics)	❌ Not available	PCS 7 wins
Digital Twin	SIMATIC Mimic / SIMIT (simulation & training)	❌ Not available	PCS 7 wins
MES	Syncade (electronic batch records)	❌ Not native (REST API integration point)	PCS 7 wins
AI/ML	Siemens AI / analytics portfolio	❌ Not available	PCS 7 wins
Edge Computing	PCS neo (next-gen web DCS, separate product)	QB Edge (runs QB Control locally)	Different approach, both valid

Key Observation: SIMATIC APL vs. QB Services

SIMATIC APL (Advanced Process Library) — PCS 7’s nearest analog to QB Services — contains 300+ pre-built function blocks for generic process control (PID, cascade, feedforward, sequencing). However, APL blocks are generic process primitives, not bioprocess-specific, and each bioprocess application still requires custom CFC/SFC design to orchestrate them into a cohesive control strategy (typically 2–4 weeks for a standard fermentation controller, PCS 7 expert required).

QB Services are ~40 pre-built bioprocess-specific templates. Each service is a complete control strategy (e.g., “pH Control by Base & CO₂” with PID tuning, setpoint ramps, and safety interlocks); the scientist selects, configures, and runs. The fundamental gap: APL is a toolkit; QB Services are ready-to-deploy applications.

7. Services Catalog & Rapid Deployment

QB Control’s Services Catalog — A Game-Changing Differentiator

One of QB Control’s most powerful advantages over PCS 7 is the Services Catalog — a library of pre-built, parameterized service templates that can be loaded and executed within minutes. A Service is a pre-defined control action (the equivalent of a DCS control loop) that directly commands hardware. Services come in two types:

Autocomplete Services — execute a discrete task and close automatically (e.g., Transfer Volume by Pump, Add Gas Volume by MFC)
Continuous Services — run until explicitly stopped (e.g., Set Agitator Speed, Temperature Control by TCU, pH Control by Base & CO₂)

Services Catalog by Category

QB Control ships with ~40 pre-built service templates across 10 functional categories out of the box, with QB Filtration adding a tangential-flow filtration set (recently expanded). This covers every core bioprocess control need:

Category	Example Services	Count	Types
pH Control	pH Control by Base & CO₂, by Base & Acid, by One Pump, One Pump PID, pH PID Control	6	Continuous
Temperature Control	by TCU, by Heating Mat, by Steam & Water, Split Temp, Set Circulator Temp, Set Heating Mat Power	6	Continuous
Pump & Feed	Feed, Autosubstrate, Set Pump Flow Rate, Set Centrifugal Pump RPM, Transfer Volume/Bolus, Gravimetric Feeding	9	Continuous + Autocomplete
Gas Control	O₂ Control, Advanced O₂ Control, Set MFC Flow, Set Sparger Mass Flow	4	Continuous
Gas Volume Delivery	Set Sparger Volume & Mass Flow	1	Autocomplete
Sampling	Automated Sampling, Sample by Syringe Pump, Sampler Cleaning	3	Continuous + Autocomplete
Stirring & Agitation	Stirring, Set Agitator Speed	2	Continuous
Foam Control	Foam Control, Foam Control by Antifoam Reagent	2	Continuous
Valve Control	Set Selector Valve Position, Set Valve Position	2	Continuous
LED & Light	LED Control, LED Control Scheduler	2	Continuous
Core catalog (out of the box)		~40	across 10 categories
QB Filtration add-on	Filtervig Control, Concentration Factor Logic, NWP Calculator, Breakthrough Detection, plus six new tangential-flow services	expanded	Continuous + Autocomplete

Service Profiles — Reusable Parameter Templates

QB Control’s Service Profiles (Settings → Service Profiles) let users save standardized parameter configurations as reusable templates. QB Control adds grouped and atomic-style configuration models, structured profile cards (e.g., PID Controller Tuning, Temperature Ramp, Operating Limits), and portable export/import to transfer complete profile sets between templates or environments. Profile-driven values are labeled in execution review for traceability.

How Services Transform Experiment Deployment

Workflow Step	PCS 7 Approach	QB Control with Services Catalog
Define control strategy	Write IEC 61131-3 code or configure APL function blocks in CFC	Select service template from catalog
Set parameters	Enter values in Control Studio CFC editor (trained PCS 7 engineer)	Load a saved Service Profile or enter values in a visual form
Change control logic	Reprogram APL blocks, re-validate CFC, re-test	Swap service template — minutes, not days
Deploy to process	Commission in TIA Portal, configure PROFINET addresses, test, validate — weeks	Add service to process; it appears in Recipe Designer — minutes
Try a different strategy	New engineering engagement	Select a different service / apply a different profile — instant

Time-to-Deploy for Experiment Strategy Changes

Scenario	PCS 7 Time	QB Control Time	QB Advantage
Switch pH control from CO₂+Base to Acid+Base	2–3 weeks (reprogram APL, CFC redesign, validate)	5 minutes (swap service template)	~200× faster
Add foam control to an existing process	2–3 weeks (add ET 200 I/O, reprogram CFC, commission)	10 minutes (add service + connect foam sensor)	~150× faster
Change temperature control from setpoint to ramp	1–2 weeks (modify CFC PID block, add ramp logic)	2 minutes (change parameters or swap template)	~500× faster
Deploy a completely new experimental strategy	4–8 weeks (full PCS 7 engineering cycle)	1–2 hours (select services, build recipe, validate)	~200× faster
Replicate a proven setup to a new bioreactor	2–4 weeks (copy PROFINET config, re-commission ET 200s, re-validate CFC)	15 minutes (Process Import/Export + device mapping + Profiles)	~100× faster

This is a capability PCS 7 simply cannot match at the lab/pilot scale. PCS 7 requires engineering effort (IEC 61131-3 reprogramming, CFC redesign, commissioning, validation) for every control strategy change; QB Control makes it a catalog selection.

8. Recipe Engine

Overview

The Recipe Module is the core automation engine of QB Control. It translates biotechnological protocols into executable digital workflows by combining logic blocks and Services (hardware actions), through three integrated boards: Designer Board (create/edit), Batch Board (configure/execute), and Executions Board (monitor history). SIMATIC BATCH is PCS 7’s ISA-88 batch execution framework, structuring batches into Procedures, Unit Procedures, Operations, and Phases — a formal, top-down procedure hierarchy.

8.1 Designer Board & the Unified Block Library

The Designer Board is a visual, drag-and-drop workspace for building process logic as a connected flow. QB Control consolidates the previous per-service blocks into a unified block library with built-in grouping, descriptions, tooltips, and embedded in-app guidance:

Block	Category	Function
Start Service	Service Control	Single configurable block (replaces many per-service start blocks); pick the service at configuration; supports Autocomplete (run-to-completion) and Continuous (keep running)
Stop Service	Service Control	Explicitly stop a continuous service later in the flow
Update Service Inputs	Service Control	Change service input values mid-execution (startup vs. runtime-adjustable inputs kept separate)
Service Profile support	Service Control	Start/Update blocks accept preset profile configurations; profile values labeled in execution review
Manual Operation	Operations	Pause for operator-driven action where supervised intervention is required
Variable / Update Variables	Variables	Declare named values (boolean, text, number, time); update with increase / decrease / multiply / divide
Timer	Timing	Shared timer control with start / stop / pause / resume modes
Set Valve State	Equipment commands	Command valve positions directly as part of the sequence
Conditional	Logic & flow	Evaluate real-time variables with AND / OR expressions
Counter	Logic & flow	Loop control with iteration count
PID	Logic & flow	Inline PID-oriented control block
Polygon	Logic & flow	Piecewise-linear mapping (X→Y) for ramps and profiles
Split / Merge	Logic & flow	Fork into parallel paths and join them back together
Wait / Wait Until / Start / Stop / End	Standard	Time-based pause, condition-based pause, and execution control

Authoring productivity: copy/paste of blocks, signal filtering for cleaner input selection, undo/redo, diagram export (image), and recipe import/export across installations. The designer flags inactive recipes that should not be started as-is.

Recipe state lifecycle: Draft → Verified → Validated → Hold → Archived. Critically, only Verified or Validated recipes can run in batches — not just Validated — which streamlines development without weakening control.

8.2 Batch Board

Create batches for processes and assign single or multiple recipes per batch
Real-time view to monitor and control execution (stop, pause, resume)
Sequential batch execution with Pending status for queued batches and auto-stop configuration per batch
Edit parameters from the execution board where permitted — no round-trip to the designer mid-run
Step execution counts and live recipe status updates

8.3 Executions Board

List of executed batches with start/finish time, status, and configuration
Statuses: During Execution, Paused, Hold, Pending, Completed, Failed, Aborted
Filter by System, Process, Status; export list to CSV; export recipe flow to PNG
Direct links to the live view of currently executing recipes

8.4 Validation & Safety

The Validator — visual workspace for verifying recipe logic before execution
Automated pre-start validations prevent batch collisions, unauthorized recipe starts, and execution on disconnected hardware
Mandatory pre-execution checklist forces operators to verify critical lab elements (tubing integrity, media preparation, wetware) before start — an enforced safety gate SIMATIC BATCH leaves optional
License guard — creating, duplicating, or importing recipes is blocked when the recipe license limit is reached
Emergency integration — runs hold or abort safely when a P-Stop or global E-Stop is active

8.5 Recipe Engine vs. SIMATIC BATCH — Detailed Comparison

Capability	SIMATIC BATCH	QB Control Recipe Engine
Workflow design	IEC 61131-3 + ISA-88 procedural model (semi-visual SFC; trained engineer)	Visual drag-and-drop Designer Board (no coding)
Parallel execution	Batch Executive with unit arbitration	Split/Merge blocks for parallel paths
Sequential campaigns	Campaign Manager	Sequential batches with Pending queue + auto-stop
Conditional logic	SFC transitions (state-dependent)	Conditional blocks with AND/OR on real-time data
Variables & math	Custom CFC function blocks	Variable / Update Variables (increase/decrease/multiply/divide)
Timers	SFC step timing	Timer block (start/stop/pause/resume)
Human-in-the-loop	Manual phase prompts	Manual Operation block
Execution monitoring	SIMATIC BATCH Monitor (Windows, proprietary UI)	Batch Board with real-time, color-coded status (browser)
Recipe versioning	Recipe library + document-centric approvals	Draft → Verified → Validated → Hold → Archived
Pre-execution safety	Operator checklist (optional, not system-enforced)	Mandatory checklist + Validator (system-enforced)
Ramp/profile control	Custom CFC/ST function blocks	Polygon block + service ramp parameters
Diagram export	Not standard (custom scripts)	Export as image / PNG for compliance docs
Time to create recipe	Days to weeks (engineering + validation)	Minutes to hours (visual, no-code)

Key Insight: Visual vs. Formal

SIMATIC BATCH advantage: perfect ISA-88 compliance enables formal technology transfer from lab recipe to production batch recipe, with recipe structure standardized across all SIMATIC BATCH users. QB Control advantage: scientists author their own recipes without control-engineering expertise; recipes encode domain knowledge visually, making them self-documenting and audit-friendly — and editable in minutes.

9. Regulatory Compliance

Standard	PCS 7	QB Control	Notes
FDA 21 CFR Part 11	✅ Full compliance	⚠️ Partial conformance	PCS 7: full (with e-sigs via WinCC). QB: electronic records, audit trails, access control, user management today — electronic signatures not yet covered
EU Annex 11	✅ Full compliance	✅ Compliance support	Both provide computerized-system validation capabilities
GAMP 5	Category 5 (custom CFC/SFC code)	Category 4 (configurable)	QB Control has lower validation burden — no custom code to validate
ISA-18.2 (Alarms)	✅ Full compliance	✅ Conformance	Both support suppressed, out-of-service, acknowledgement workflows
ISA-88 (Batch)	✅ Full compliance (best-in-class)	⚠️ Follows batch concepts; not formally ISA-88 certified	PCS 7 stronger for formal ISA-88 compliance
ALCOA+ (Data Integrity)	✅ Full implementation	✅ Full implementation	Both provide ALCOA+ data integrity
Electronic Signatures	✅ Built-in (cryptographic, via WinCC)	◐ On roadmap (Q3 2026 — not in current version)	PCS 7 leads; QB planned
Audit Trail	✅ Event Chronicle (immutable)	✅ Immutable, exportable (CSV), cross-module, searchable	Both comprehensive
Safe Position Logic (GMP)	Via interlock engineering in CFC	✅ Built-in — define safe actuator states after restart/power cycle	QB has a dedicated, configurable feature
CE Marking	System-level	✅ Per QB Module (EMC + Low Voltage Directive)	Each module ships its own Declaration of Conformity

Compliance Value for QB Control

GAMP 5 Category 4 vs. Category 5 is the key differentiator. As configurable (not custom CFC/SFC) software, QB Control needs a reduced validation scope and standardized test scripts rather than full custom IQ/OQ/PQ with code review — roughly 50–70% less validation effort, faster time to GMP-ready operation (weeks vs. months), lower CSV cost, and simpler change management (configuration changes, not code changes that trigger re-validation).

Honest Compliance Caveat

QB Control’s 21 CFR Part 11 conformance is partial: it delivers electronic records, audit trails, access control, and user management today, but electronic signatures are not yet implemented (roadmapped for Q3 2026). For workflows that require digital signatures on an active IND today, PCS 7 remains the safer choice until QB Control’s e-signature release. Do not represent QB Control as fully 21 CFR Part 11 compliant.

10. Pricing, Licensing & TCO

Direct Cost Comparison

Cost Component	PCS 7	QB Control	Savings with QB
Entry-Level System	EUR 80K–150K+ (engineering license + AS 410 + I/O + integrator)	QB Edge + basic modules + license: ~$15,000–25,000	70–85%
Typical Lab Setup (4 bioreactors)	EUR 200K–450K+ (full system + BATCH + validation)	4× bioreactor module sets + QB Edge + license: ~$60,000–85,000	60–75%
6-Bioreactor Lab Setup	EUR 300K–550K+	6× bioreactor module sets + QB Edge(s) + license: ~$100,000	65–80%
Pilot Setup (8–12 bioreactors)	EUR 500K–900K+	8–12× module sets + QB Edge(s)/switches + license: ~$150,000–250,000	50–70%
System Integrator Cost	EUR 75K–250K+ per project (500–1,200 hrs)	$0 (self-setup, plug-and-play)	100%
Workstation Hardware	Approved-vendor PCs + CALs, $5,000–$15,000 per station	$0 (any existing device with a browser)	100%
Software License	Per-PO count + separate engineering/OS/BATCH modules; recurring SUS	Perpetual license (one-time purchase)	Significantly lower long-term
Training	6+ weeks formal training (Siemens Academy, EUR 5K–15K+)	QB Systems Online Portal + documentation — self-paced	80–90%
Validation (GAMP 5)	Category 5 — extensive IQ/OQ/PQ + code review (EUR 60K–150K)	Category 4 — reduced scope ($10,000–$50,000)	50–75%
Wiring & Installation	Marshalling cabinets, ET 200 racks, cable trays, terminations	PoE — one cable per module (benchtop)	80–90%

Total Cost of Ownership (5-Year Projection)

Scenario: 6-bioreactor parallel upstream processing lab

TCO Component	PCS 7 (5-Year)	QB Control (5-Year)
Hardware (AS 410 + ET 200 vs. QB Modules + QB Edge)	$200,000	$100,000
Software licensing	$100,000 (per-PO + SUS escalation)	$30,000 (perpetual, one-time)
Paid support & maintenance (SUS ~15–20%/yr)	$150,000 (~$30K/yr)	$25,000 (tiered support plan)
System integration (Solution Partner)	$120,000	$0
Installation & wiring (marshalling, PROFINET)	$40,000	$5,000
Validation (GAMP 5 Cat 5 vs. Cat 4)	$80,000	$20,000
Training (Siemens Academy vs. Online Portal)	$30,000	$5,000
TOTAL	~$720,000	~$185,000
		~74% lower TCO

Hidden Costs in PCS 7

Often overlooked, these add EUR 25K–50K+ over 5 years: Windows CALs per HMI seat; DBA support for the MSSQL historian; network engineering (PROFINET commissioning, PROFIBUS segment management, firewall rules for OPC); change-management consulting (Category 5 code changes trigger re-validation); hardware refresh cycles for workstations and AS 410 hardware; hot-standby redundancy (FMR) setup; and version-upgrade cycles (major Siemens releases every 2–3 years often require re-licensing and re-validation). QB Control eliminates all of these — browser-based means no CALs, no workstation refresh, no DBA, no Windows licensing; perpetual licensing means no forced version upgrades.

Licensing Model Comparison

Aspect	PCS 7	QB Control
Model	Per-PO point count (100/1,000/5,000) + separate engineering/OS/BATCH modules + CALs	Perpetual license — feature-, device-, system/process-, and time-based dimensions
License Type	Per-PO with mandatory SUS (annual ~15–20%)	Perpetual — buy once; no recurring license fees
Support	Bundled or via SUS (mandatory for updates)	Paid separately — tiered (Basic, Standard, Premium), client’s choice
Additional Features	Add per-module / per-PO cost	Priced transparently upon request
Enforcement	SIMATIC License Key (hardware-locked, per-feature)	Software license bound to the deployment host; license-aware UI and guards surface limits
Multi-Site	Separate license per site (plant-wide deployments multiply costs)	Single license per host; multi-host requires additional licenses
Lock-In	Tied to Siemens hardware (AS 410, ET 200, PROFINET)	Not tied to a specific hardware vendor
Hardware Dependency	Approved-vendor workstations + CALs; AS 410 controllers	Any browser-capable device; QB Edge or industrial PC

Licensing Model — Key Client Value

No recurring license fees — the perpetual license does not expire, eliminating PCS 7’s annual SUS burden (~15–20% of license cost/year)
Paid support is optional and tiered — no forced bundling, no mandatory SUS
Additional capabilities priced transparently on request, not hidden behind per-PO licensing tiers
Predictable budgeting — one-time license + optional support; no forced version-upgrade re-licensing
No “license hostage” risk — perpetual model means a lapsed contract never locks you out of your own system

11. Industry Fit Analysis

Biotech (Lab & Pilot Scale)

Criterion	PCS 7	QB Control	Winner
Cell culture (150 mL–10 L)	Over-engineered	Purpose-built	QB Control
Fermentation (1–50 L)	Capable but expensive	Native support	QB Control
Parallel bioreactors (lab)	32+ per network	Multiple processes, auto-generated P&IDs	QB Control (simpler, cheaper)
Stainless-steel pilot (PLC)	Full DCS	Industrial-PC deployment + OPC-UA (new)	QB Control (right-sized)
Process development / DoE	Capable but SI-dependent	Rapid reconfiguration, import/export	QB Control
Single-use bioprocessing	Sartorius STR Gen 3 integration	Native SU pump heads, SU pressure sensors	QB Control (more flexible)
Production scale (>200 L, multi-train)	Full production-grade DCS	Single-site focus	PCS 7
Technology transfer to CMO	ISA-88 recipe portability (industry standard)	Process/recipe import/export + device mapping	PCS 7

Pharmaceuticals

Criterion	PCS 7	QB Control	Winner
R&D lab automation	Over-engineered	Right-sized	QB Control
Process development	Good but expensive	Faster iteration, lower cost	QB Control
QC lab automation	Not typical use case	Good fit	QB Control
GMP production (small scale)	Full compliance	CFR Part 11 partial (no e-sigs yet)	PCS 7 (e-sigs today)
GMP production (large scale)	Proven at 20,000+ L, 25+ years	Not designed for this	PCS 7
Continuous manufacturing	PredictPro MPC + SIMATIC PAT	Not supported	PCS 7

Cosmetics

Criterion	PCS 7	QB Control	Winner
Formulation development	ISA-88 batch — overkill	Visual recipe designer — right-sized	QB Control
Small batch production	Capable but expensive	Affordable with compliance support	QB Control
Multi-product flexibility	Good batch engine	Process reconfiguration in minutes	QB Control
Scale-up to production	Proven path	Limited to pilot/early production	PCS 7

Food & Beverage

Criterion	PCS 7	QB Control	Winner
Small-scale fermentation (10–100 L)	Over-engineered	Purpose-built	QB Control
Speed to deploy a new recipe	6–10 weeks	1–2 weeks	QB Control
Hardware modularity (seasonal vessels)	Fixed design	Plug-and-play PoE modules	QB Control
Plant-wide utilities / large lines	Full DCS	Not designed for this	PCS 7

Academic / Research

Criterion	PCS 7	QB Control	Winner
Teaching labs	Far too expensive	Affordable, visual, intuitive	QB Control
Research bioprocessing	Expensive, slow to set up	Fast, modular, reconfigurable	QB Control
Multi-student access	Licensed per workstation (CALs)	Any browser, multi-user concurrent	QB Control
Publication-ready data	Historian + InfoBatch	Graphs export (SVG, PNG, CSV) + Reports (PDF, DOCX)	Tie

12. What QB Control Can Replace

Full Replacement Scenarios

1. Lab-Scale Bioreactor Control (150 mL–10 L) — PCS 7 lab system (AS 410 + ET 200 + WinCC) → QB Edge + QB Modules. Value: 85% cost reduction, days vs. months setup, no SI, browser-based access.

2. Parallel Small-Scale Fermentation — PCS 7 multi-unit ISA-88 setup → QB Control multi-process with QB Multiagitator. Value: plug-and-play parallel, auto-generated P&ID per process, sequential auto-stop campaigns, lower incremental cost per vessel.

3. Stainless-Steel Pilot Cells with Existing PLCs (new) — PCS 7 controller layer → QB Control on an industrial PC integrating the PLC via OPC-UA + the OPC UA Connector. Value: reuse field hardware, no DCS license, no SI re-engineering.

4. Automated Sampling Systems — PCS 7 + custom CFC sampling → QB Selector Valve (24 positions) + QB Syringe Pump + recipe. Value: native sampling workflow, visual recipe design.

5. Media Preparation Stations — PCS 7 batch → QB Pumps + Scales + Agitator + recipe. Value: modular, reconfigurable, fraction of cost.

6. pH/DO/Temperature Control Loops — PCS 7 PID loops with HART/PROFIBUS sensors → QB Multisensor (Hamilton/MT) + QB Gasflow + QB Thermo + services. Value: native sensor integration, no adapters, no Fieldbus complexity.

7. Process Development & DoE — PCS 7 configuration + STEP 7 engineering → QB Control process import/export + device mapping + rapid reconfiguration. Value: change setups in minutes, run different configs on parallel vessels.

8. Single-Use Bioprocessing — PCS 7 with Sartorius STR Gen 3 → QB Modules with SU pump heads and SU pressure sensors. Value: more vendor flexibility, lower cost, simpler setup.

Partial Replacement Scenarios

9. Pilot-to-Early-Production Upstream (10–200 L) — QB Control handles monitoring, control, and automation; PCS 7 may still be needed for complex cascade control, APC, or MPC. Value: QB Control as primary platform with an OPC-UA bridge to PCS 7 for advanced functions.

10. Small-Scale GMP Production — QB Control provides partial 21 CFR Part 11 conformance (records, audit trails, RBAC, data integrity; e-signatures on roadmap). Value: lower validation burden (GAMP 5 Category 4), but may require additional qualification documentation and an e-signature bridge until Q3 2026.

13. Where QB Control Creates Superior Value

13.1 Time-to-Process

Metric	PCS 7	QB Control	Improvement
System setup	12–16 weeks	< 1 week	90%+ faster
Add a bioreactor	2–4 weeks	< 1 day	95% faster
Recipe modification	Days–weeks (qualified PCS 7 engineer)	Minutes (visual drag-and-drop)	90% faster
New process configuration	Days–weeks	Hours (import/export or visual config)	80% faster

13.2 Value Summary

Each pillar is detailed in the section noted; in brief, QB Control delivers:

Lowest TCO — ~74% lower 5-year cost for a 6-bioreactor lab ($185K vs. $720K), perpetual license with no mandatory SUS, no system integrator, no licensed workstations or CALs (§10).
No vendor lock-in — open sensors and consumables, open protocols, or reuse of existing PLCs instead of AS 410 / ET 200 / PROFINET (§5).
Operational simplicity — browser-based (no CALs), auto-discovery, no-code recipes, multi-user access, and a single Health Monitoring dashboard (§3, §6).
Instant strategy changes — ~40 pre-built services and reusable Service Profiles let scientists swap a control strategy in minutes, not weeks of APL/CFC reprogramming (§7).
Modern, open integration — native OPC-UA, REST, MQTT, SQL, MTP, and secure remote access with QR-code setup (§5).
Right-sized safety & governance — P-Stop/E-Stop, Safe Position Logic, and a mandatory pre-execution checklist + Validator (§8).

14. Gaps & Limitations

PCS 7 Capabilities Not Available in QB Control

Capability	PCS 7	QB Control	Impact
Model Predictive Control (MPC) / APC	PredictPro (economic optimizer)	Not available	High
PAT Integration	SIMATIC PAT (embedded chemometrics)	Not available	High
Digital Twin / Simulation	SIMATIC Mimic / SIMIT	Not available	Medium
ISA-88 Full Compliance	Best-in-class, formally certified	Follows batch concepts; not formally certified	Medium
MES Integration	Syncade (native EBR, ERP/LIMS)	REST API integration point	Medium
AI/ML	Siemens AI / analytics portfolio	Not available	Medium
Production Scale (>200 L, multi-train)	Proven at 20,000+ L	Single-site, lab-to-pilot/early-production focus	High
Enterprise Multi-Site	Plant-wide DCS with enterprise historian	Single-site (networkable)	High
Electronic Signatures	Built-in (via WinCC)	On roadmap (Q3 2026)	High for regulated production today
SIL-rated Safety (SIS)	SIL 3 via S2 / FMR redundancy	Not SIL-rated	Medium
Foundation Fieldbus / HART	Native	Not supported (sensors via Modbus RS485)	Low (declining protocols)
Batch Analytics	InfoBatch cross-batch statistics	CSV export for external analysis	Medium

Honest Assessment of QB Control Limitations

Scale ceiling — optimized for lab-to-pilot and early stainless-steel production; very large multi-train production still favors a full DCS
No MPC/APC — multivariable predictive control with an economic optimizer is not available
No PAT — inline spectral analysis and chemometric models are not embedded
No digital twin — simulation and operator-training capabilities are absent
No native MES — electronic batch records require integration with an external MES (e.g., Syncade)
No electronic signatures yet — 21 CFR Part 11 conformance is partial until the Q3 2026 release
ISA-88 not formally certified — QB Control follows batch concepts but is not formally certified, which some large pharma may require
Liquid-handling focus — QB Control does not address gas-phase, solid-phase, or complex hybrid processes; no PROFIBUS/HART/Foundation Fieldbus legacy field integration

15. Migration & Replacement Scenarios

Scenario A: Greenfield Lab (No Existing PCS 7)

Recommendation: QB Control. New lab from scratch = no migration, no legacy. QB Control provides everything needed for lab/pilot bioprocessing, ~85% cost savings vs. PCS 7, operational in days — no AS 410, no ET 200, no Solution Partner.

Scenario B: PCS 7 Lab Seeking Modernization

Recommendation: QB Control replacement. Replace aging PCS 7 lab/pilot systems with QB Control; maintain PCS 7 for any connected production systems; bridge via OPC-UA if needed. ROI typically recovered in <12 months through eliminated SUS, CAL, and SI costs.

Scenario C: Stainless-Steel Pilot Cell with an Existing PLC

Recommendation: QB Control on an industrial PC. Deploy QB Control on an industrial PC, integrate the existing PLC over OPC-UA via the OPC UA Connector, and keep the field instruments. Value: DCS-class supervisory control and recipes without the DCS price, PROFINET lock-in, or SI re-engineering.

Scenario D: Expanding Parallel Capacity

Recommendation: QB Control for new vessels. Keep existing PCS 7 for current bioreactors; add parallel capacity with QB Control + QB Modules; no impact on validated PCS 7 systems; OPC-UA bridge for unified data if needed.

Scenario E: CDMO Scaling Up Client Projects

Recommendation: QB Control for client-facing process development. Rapid setup/teardown for different client processes; process import/export + device mapping for fast replication; perpetual license applies across all client projects (no per-site SUS); PCS 7 retained for production-scale manufacturing.

Scenario F: Academic / Research Institution

Recommendation: QB Control (full replacement). PCS 7 is prohibitively expensive for teaching/research; QB Control provides professional-grade control at accessible cost, multi-student browser access (no per-seat CAL licensing), and modular hardware for curriculum flexibility.

16. Competitive Positioning Strategy

Positioning Statement

QB Control is not competing with PCS 7 across the entire spectrum. QB Control is replacing the portion of PCS 7 that was never designed for lab and pilot-scale bioprocessing. Siemens PCS 7 is a plant-wide DCS built for enterprise manufacturing, multi-site operations, and production-scale batch control. QB Control is a modular SCADA platform built specifically for the bench, the hood, the pilot hall — and now, with its industrial-PC deployment, the stainless-steel pilot cell that already has a PLC. When a lab spends $720K over 5 years running 6 bioreactors on PCS 7, they’re buying a Boeing 747 to commute to work. QB Control delivers the same bioprocessing capability for $185K with a perpetual license, no system-integrator dependency, and a Services Catalog that lets scientists change experimental strategies in minutes, not weeks.

Key Sales Arguments Against PCS 7

PCS 7 Pain Point	QB Control Advantage	Evidence
”PCS 7 costs EUR 300K+ for a 6-bioreactor lab”	Complete 6-bioreactor lab for ~$100K hardware + perpetual license	~74% lower 5-year TCO
”Siemens SUS fees never stop (~15–20%/yr)“	Perpetual license — buy once, use forever	No recurring license costs
”Changing our pH control strategy takes weeks”	Swap a service template in 5 minutes	~200× faster strategy changes
”We waited 12–16 weeks for our PCS 7 system”	Unbox Monday, first experiment Friday	Plug-and-play, auto-discovery
”We need a Solution Partner for any change”	Visual recipe designer + Services Catalog, self-service	No coding, no SI dependency
”PCS 7 requires Windows OS servers + CALs”	Any browser on any device	Zero client infrastructure
”Our Foundation Fieldbus / PROFIBUS keeps failing”	PoE auto-discovery; or clean OPC-UA to your PLC	Zero Fieldbus complexity
”PCS 7 validation took 6 months (Cat 5)“	GAMP 5 Cat. 4, validated in weeks	50–75% validation reduction
”We’re locked into the SIMATIC ecosystem”	Open sensors, open consumables, open protocols, MTP	No vendor lock-in at any level
”We can’t access the system remotely without IT”	Secure remote access with QR-code setup	Phone/tablet/PC, role-based
”Adding a bioreactor means new AS 410 + ET 200”	Add modules + expand license (one-time)	Fraction of incremental cost

When NOT to Position Against PCS 7

Do NOT position QB Control against PCS 7 when the client needs:

Production-scale, multi-train manufacturing (>200 L)
Model Predictive Control / advanced process control (APC) or process optimization
PAT/spectral integration for continuous manufacturing
Enterprise multi-site DCS deployment
Safety Instrumented Systems (SIL 3-rated)
Formal ISA-88 certification
Electronic signatures on an active IND today (before QB Control’s Q3 2026 release)
Integration with existing plant-wide MES/ERP (Syncade/SAP) or legacy PROFIBUS/HART field devices

In these cases, position QB Control as complementary to PCS 7 — handling lab/pilot while PCS 7 handles production, bridged over OPC-UA.

17. Feature-by-Feature Matrix

#	Feature	PCS 7	QB Control	QB Advantage	Notes
CORE CONTROL
1	Bioreactor control	★★★★★	★★★★		PCS 7: APC/MPC; QB: PID-based services
2	Mixer/agitator control	★★★★★	★★★★★	✅	QB native agitator modules (up to 6 vessels)
3	Pump control	★★★★	★★★★★	✅	QB: 4 pump types native + SmartPump OPC
4	Sampler control	★★★★	★★★★★	✅	QB: native selector valve (24 positions)
5	Gas flow control	★★★★	★★★★		QB native; PCS 7 3rd-party MFC
6	Temperature control	★★★★★	★★★★		PCS 7: broader range; QB: 2–42 °C
7	Valve control	★★★★	★★★★★	✅	QB: Set Valve State block + three-way valves
8	Scale/weight measurement	★★★	★★★★★	✅	QB: native multiscale (6 channels)
9	Foam detection	★★	★★★★★	✅	QB: patent-pending optical sensor
10	LED/light control	★	★★★★★	✅	PCS 7: not in ecosystem; QB: native
PARALLEL PROCESSING
11	Multi-device parallel	★★★★★	★★★★		PCS 7: more vessels at production scale
12	Sequential campaign queuing	★★★★★	★★★★		QB: Pending queue + auto-stop (new)
13	Auto-generated P&ID per process	★★	★★★★★	✅	QB auto-generates; PCS 7 manual WinCC
14	Process import/export + device mapping	★★★	★★★★★	✅	QB: one-click replication + remap
15	Multi-user concurrent access	★★★	★★★★★	✅	QB: any browser; PCS 7: per-CAL stations
RECIPE, BATCH & SERVICES
16	Recipe management	★★★★★	★★★★		PCS 7: ISA-88 formal; QB: visual
17	Visual recipe designer	★★	★★★★★	✅	QB: drag-and-drop, no coding
18	Recipe versioning	★★★★	★★★★★	✅	QB: Draft→Verified→Validated→Hold→Archived
19	Services Catalog	★★	★★★★★	✅	QB: ~40 services across 10 categories; PCS 7: APL generic blocks
20	Service Profiles (reusable params)	★★	★★★★★	✅	QB: grouped/atomic + portable import/export
21	Variables / Timer / Manual blocks	★★★	★★★★★	✅	QB: unified block library (new)
22	Strategy switching speed	★★	★★★★★	✅	QB: swap service in minutes
23	Batch Board (execution tracking)	★★★★★	★★★★★		Both strong; QB adds flow-diagram export
24	Pre-execution safety checklist	★★★	★★★★★	✅	QB: mandatory + Validator (system-enforced)
25	Campaign / batch analytics	★★★★★	★★★		PCS 7: InfoBatch built-in analytics
INTEGRATION
26	OPC UA	★★★★	★★★★★	✅	QB: native + dedicated OPC UA Connector
27	REST API	★	★★★★★	✅	QB native; PCS 7 lacks
28	MQTT	★	★★★★★	✅	QB native; PCS 7 needs gateway
29	SQL access	★★	★★★★★	✅	QB native JDBC/ODBC
30	LDAP/AD SSO	★★★	★★★★★	✅	QB native; PCS 7 via Windows
31	MTP support	★★★★	★★★★		Both support; PCS 7 more mature tooling
32	Hamilton / Mettler Toledo sensors	★★★	★★★★★	✅	QB: direct via Modbus RS485
33	PLC reuse (Wago/Siemens/Beckhoff)	★★★	★★★★★	✅	QB: industrial-PC deployment (new)
COMPLIANCE
34	21 CFR Part 11	★★★★★	★★★★	⚠️	PCS 7 full; QB partial (no e-sigs yet)
35	GAMP 5 classification	Cat. 5	Cat. 4	✅	QB: lower validation burden
36	ISA-18.2 alarms	★★★★★	★★★★		Both conform
37	Audit trail	★★★★★	★★★★★		Both comprehensive
38	Electronic signatures	★★★★★	★★	⚠️	PCS 7 full; QB roadmap Q3 2026
39	Safe Position Logic (GMP)	★★★	★★★★★	✅	QB: built-in configurable feature
USABILITY & OPS
40	Setup time	★★	★★★★★	✅	QB: 90%+ faster
41	Learning curve	★★	★★★★★	✅	QB: no formal training; PCS 7: 6+ weeks
42	Documentation quality	★★★	★★★★	✅	QB browser help + portal
43	Client device flexibility	★★	★★★★★	✅	QB: any browser; PCS 7: licensed PCs
44	Remote access	★★★	★★★★★	✅	QB: secure VPN + QR setup (new)
45	Health monitoring dashboard	★★★	★★★★★	✅	QB: consolidated module/host health (new)
46	Configuration approach	★★	★★★★★	✅	QB: visual, no code
COST & LICENSING
47	Initial investment	★★	★★★★★	✅	65–80% lower (6-bioreactor)
48	5-year TCO	★★	★★★★★	✅	~74% lower TCO
49	License model	★★	★★★★★	✅	QB perpetual; PCS 7 per-PO + SUS
50	Incremental expansion cost	★★	★★★★★	✅	Fraction of cost
51	SI dependency	★★	★★★★★	✅	QB: self-service
52	Vendor lock-in	★★	★★★★★	✅	QB: open ecosystem
ADVANCED CAPABILITIES
53	MPC / APC	★★★★★	❌		PCS 7 exclusive (PredictPro)
54	PAT spectral	★★★★★	❌		PCS 7 exclusive
55	Digital twin	★★★★	❌		PCS 7 exclusive (Mimic/SIMIT)
56	MES	★★★★★	★★		PCS 7: native Syncade
57	AI/ML	★★★★	❌		PCS 7 exclusive
58	SIL safety	★★★★	❌		PCS 7 exclusive
59	Enterprise multi-site	★★★★★	★★		PCS 7 exclusive

Summary Scores by Category

Category	PCS 7 Average	QB Control Average	Winner
Core Control	3.9	4.5	QB Control
Parallel Processing	3.8	4.6	QB Control
Recipe, Batch & Services	3.5	4.7	QB Control
Integration	2.9	4.8	QB Control
Compliance	4.6	4.3	PCS 7 (e-sigs today)
Usability & Ops	2.4	4.9	QB Control
Cost & Licensing	2.0	5.0	QB Control
Advanced Capabilities	4.6	0.3	PCS 7

Overall: QB Control wins in 6 of 8 categories for the target lab/pilot/early-production market. With its unified recipe block library, sequential auto-stop campaigns, native MTP, secure remote access, Health Monitoring, and the industrial-PC deployment path, QB Control’s lead in Recipe/Batch, Integration, Usability, and Cost widens. PCS 7 retains the lead in compliance maturity (electronic signatures today) and advanced capabilities (MPC/APC, SIMATIC PAT, digital twin, SIL safety, enterprise multi-site) — primarily relevant at production scale.

Recent QB Control Enhancements (current release)

The current QB Control release adds the capabilities referenced in this comparison (reflecting the current QB Control release):

Batch scheduling — recurring (daily / weekly / interval) or one-time run schedules per batch, with a calendar view, named schedules, skip-on-conflict handling, and matching audit-trail records.
Recipe portability — a recipe can be reassigned to a different process, automatically remapping its devices and services so a proven design moves between similar lines instead of being rebuilt.
Equipment changes from the P&ID — lab equipment can be added directly in the P&ID editor (auto-creating the matching inventory and process records), with freeform note elements and anchor-point piping connections; lab equipment can also be added or removed on already-deployed processes without creating a new process version.
Embedded OPC UA server — the OPC UA Connector can now run its own embedded OPC UA server, letting external OPC UA clients (e.g., MES, historians) read from QB Control directly.
Expanded catalog — six additional tangential-flow (cross-flow) filtration services and six new lab-equipment types (including cooling chamber, filter cassette, hollow-fiber filter, and vials holder).
Operations & safety — an alarm watchdog reconciling alarm state against live equipment values every 30 seconds; calibration that reserves the device during calibration (blocking conflicting operations); Protect / Interlock faceplate safeguards; audit-trail events filtered to the active license; and license-aware controls shown with explanatory tooltips.
Usability — an in-app Help section with guided walkthroughs and searchable content across every module; search across inventory tables; and Health Monitoring showing system start time and uptime.

Legal Notice & Disclaimer

Versions compared. This comparison is between QB Control (release 6.x, per the current QB Control release notes) and Siemens SIMATIC® PCS 7 version V9.1 (incl. SP2 updates, 2026). Feature statements in this document refer to these versions.

Accuracy and currency. The information provided in this comparison is based on publicly available data gathered on 20 July 2026. While we strive to keep this information accurate and up to date, product features, pricing, and terms are subject to change by the respective manufacturers. We make no warranties regarding the absolute accuracy of the competitor data, and a later release may add, change, or remove capabilities described here.

Trademarks. All trademarks, logos, and brand names are the property of their respective owners. All company, product, and service names used in this document are for identification and comparison purposes only, and use of these names, trademarks, and brands does not imply endorsement or affiliation. SIMATIC®, SIMATIC® PCS 7, and SIMATIC® BATCH are registered trademarks of Siemens AG. QB Control and QB Systems are brands of A4BEE Sp. z o.o.

Transparency note. This comparison is prepared, owned, and operated by A4BEE Sp. z o.o., the creators of QB Systems and QB Control. It was created to highlight how our product differs from other options on the market, based on objective, verifiable features.

Purpose and limitation of liability. This comparison is provided for informational and educational purposes only, to help readers build knowledge of the options available to them. It is not an assessment, audit, ranking, benchmark, or endorsement of the technical expertise, quality, safety, or performance of Siemens SIMATIC® PCS 7 or its vendor. A4BEE Sp. z o.o. assumes no responsibility or liability for any errors or omissions in the content, nor for any decisions made based on this information; any reliance on the comparison is at the reader’s own risk.

Comparative-advertising basis. This document is intended to align with applicable comparative-advertising and fair-use rules, including EU Directive 2006/114/EC and US nominative-fair-use principles: it compares products intended for the same needs, relies on material, relevant, verifiable, and representative features, and is not intended to mislead or to denigrate any competitor. Where a competitor capability could not be verified from public sources, it is identified as such. If you believe any statement is inaccurate or out of date, please contact [email protected] and it will be reviewed and corrected promptly.

Assumptions

To keep the comparison transparent and fair, the following assumptions and estimates were applied:

Third-party capabilities are interpreted from public vendor datasheets, brochures, manuals, and websites current at the analysis date. Where a capability was not clearly documented publicly, it is described as such (“not clearly documented,” “appears limited,” etc.) rather than asserted or denied.
Competitor pricing and total-cost-of-ownership figures are indicative estimates derived from public information and typical configurations — not vendor quotations or list prices.
QB Control reference figures are indicative, based on past quotations, and do not constitute a specific priced offer.
The comparison assumes a lab-to-pilot bioprocessing context (roughly 150 mL–50 L, plus stainless-steel pilot/production via PLC over OPC-UA); conclusions may differ at large multi-train production scale.
“QB Control” reflects the current released version at the analysis date; third-party products reflect the newest versions identified in public sources.

Sources

QB Control capabilities referenced in this document reflect QB Control release 6.x (current release).

Product and brand names listed below are trademarks of their respective owners (attributed in the Legal Notice & Disclaimer) and are used here for identification and comparison purposes only.

Analysis prepared July 2026 | Version 1.0 (v1-July) | QB Systems vs. SIMATIC PCS 7 competitive positioning QB Systems — Flexible. Innovative. Limitless. | A product brand of A4BEE Sp. z o.o. | https://qb.systems