A major pharmaceutical company struggled with manual, error-prone data extraction for monthly compliance reporting within their utilities department. The team was reliant on fragile Excel macros pulling historical LGH file data from AVEVA InTouch HMI (formerly Wonderware InTouch) systems, which frequently broke due to Microsoft Office updates, causing costly delays and requiring repeated engineering intervention.
To streamline their regulatory reporting process and ensure data accuracy and security, the pharmaceutical utilities group sought a robust, user-friendly solution to extract water and wastewater data efficiently without IT bottlenecks or operational downtime.
What Are LGH Files?
LGH files are historical data files generated by AVEVA InTouch HMI (formerly Wonderware InTouch), widely used in industrial environments to collect and archive process data such as utilities consumption, water, and wastewater metrics. They store local process history data records for tags and process values that have been configured for local logging. Because LGH files are not in a human readable format, extracting data from them can be tricky without specialized tools, making efficient access essential for utilities teams.
Delivering Automation and Data Integration Solutions for Pharmaceutical Environments
The pharmaceutical manufacturer turned to Applied Control Engineering (ACE) to implement an effective data management solution.
Applied Control Engineering, Inc. (ACE) is a leading independent systems integrator specializing in process control and automation. Founded in 1991, they have grown from a single office to a team of more than 200 engineers and support personnel across nine locations, and provide expert integration services across pharmaceuticals, chemicals, oil & gas, metals and mining, power industries, and more.
"Our reach and experience allow us to deliver tailored automation solutions across diverse industries." – Phil Wood, Senior Consulting Engineer, Applied Control Engineering (ACE)
ACE addresses operational challenges through a range of Control System Engineering services spanning the entire project life cycle – from front end engineering and design (FEED) studies, through detailed design, implementation, commissioning/startup, and on-going system support. From plant floor automation to MES, including cybersecurity and network design, ACE is committed to long-term customer success.
Simplify Monthly Utilities Compliance Reporting and Reduce Engineering Support
The primary goal was to simplify the monthly utilities compliance reporting process by providing direct and reliable access to InTouch historical data. This would reduce the reliance on fragile Excel spreadsheets and complex macros, which were prone to breaking after Microsoft Office updates. Additionally, the client wanted to minimize engineering support requirements by enabling utilities personnel to independently extract and export the necessary data. Maintaining cybersecurity compliance while improving operational efficiency was also a critical objective, ensuring the integrity and security of sensitive data throughout the process.
Excel-Based Data Extraction and Limited Direct Historian Access Impeded Efficiency
The pharmaceutical utilities team used Excel spreadsheets with complex VBA macros and DDE connections to query LGH files for compliance data. Each Microsoft Office update risked breaking these macros, leading to frequent downtime and necessitating costly engineering fixes by ACE. Cybersecurity policies limited direct access to AVEVA InTouch HMI, making data retrieval through conventional means difficult, so the fragile Excel-based process remained the status quo.
"Before LGH File Inspector, the pharma customer relied on a complex Excel spreadsheet using DDE calls to extract data for their historian, which was time-consuming and prone to manual fixes. LGH File Inspector has greatly simplified and streamlined this process." – Phil Wood, Senior Consulting Engineer, Applied Control Engineering (ACE)
Leveraging LGH File Inspector to Streamline Data Access and Empower Utilities Teams
ACE discovered LGH File Inspector by Software Toolbox and recognized its ability to overcome the client's challenges. LGH File Inspector offers a simple, intuitive interface to browse LGH tags, select time frames, and export data directly to CSV without relying on Excel macros.
Deployment was quick and seamless, allowing the utilities team to self-serve their data extraction needs and eliminate dependency on engineering support.
"From an operations standpoint, the biggest benefit is how easy LGH File Inspector is to use. Being able to simply browse through the tag list, select the time frame and duration, then save the data as a CSV file is infinitely faster and more intuitive than manually typing tag names in Excel. Without LGH File Inspector, our customer would still be stuck with that fragile Excel process — and calling for engineering support every time Microsoft Office updated and broke the macros." – Phil Wood, Senior Consulting Engineer, Applied Control Engineering (ACE)
Results Achieved: Significant Engineering Time Savings and Operational Efficiency Gains with Enhanced Compliance Data Reporting
By implementing the new solution, the pharmaceutical company achieved significant efficiency, reliability, and usability gains across key operational areas:
- Recovered over 50 hours of engineering time annually, previously spent on investigating spreadsheet errors, manually retrieving data, and validating report accuracy. Over a 5-year operation, this translates to 250+ hours of productivity gained.
- Eliminated recurring Excel macro failures, which had previously disrupted monthly reporting and required urgent troubleshooting by engineering staff. The utilities team now has a stable, repeatable workflow that doesn't depend on fragile desktop configurations or version-specific behavior.
- Streamlined compliance reporting process, ensuring accurate, auditable data can be pulled and submitted to regulators without IT or third-party integrator assistance. Reports are now delivered on time every month, with confidence in data integrity.
- Increased user satisfaction and autonomy: The utilities team can now independently access and analyze the data they need, leading to faster decision-making and greater ownership of operational performance metrics.
"LGH File Inspector has saved our client over a man-month of engineering time in the past five years. Previously, every Microsoft Office update would break their Excel macros, requiring us to visit onsite for fixes. Now, utilities staff can easily browse tags, set timeframes, and export data themselves — a huge operational time saver. Without this tool, they’d still be stuck with fragile spreadsheets and frequent support calls." – Phil Wood, Senior Consulting Engineer, Applied Control Engineering (ACE)
From an operational perspective, the utilities personnel gained greater autonomy and efficiency, as the easy-to-use LGH File Inspector enabled them to quickly produce monthly water and wastewater compliance reports without IT bottlenecks. Additionally, by avoiding direct access to the AVEVA InTouch HMI, the company has maintained cybersecurity measures while preserving accurate, auditable data access for regulatory compliance.
Unlocking Efficiency and Integration: How to Empower System Integrators
Software Toolbox offers a robust suite of tools that have been invaluable to operations for many users. From TOP Server’s extensive OPC connectivity drivers to OmniServer’s ability to create custom protocols for devices like barcode scanners and weight scales, the products and solutions available greatly expand integration capabilities. The LGH File Inspector allowed ACE to quickly access, analyze, and export data from InTouch LGH files—a task that would otherwise require complex scripting and significant time.
Overall, Software Toolbox’s solutions enable ACE to connect with a wide range of devices and simplify engineering workflows, reducing the need for custom coding and accelerating project delivery.
Ready to simplify your compliance reporting and save valuable engineering time?
Discover how LGH File Inspector can empower your team to easily access critical historical data—without the headaches of fragile spreadsheets or IT delays.
Contact Software Toolbox today to learn how our powerful, user-friendly solutions streamline data extraction and improve operational efficiency in complex pharmaceutical environments.
