Batch Control

Consistent Execution of Batch Processes

Successful batch manufacturing is based on the reliable and consistent execution of recipes. The ISA-88 standard on batch control Part 1 provides standard models and terminology for defining the control requirements for batch manufacturing plants. The models and terminology defined in the standard:

• Emphasize good practices for the design and operation of batch manufacturing plants.
• Can be used to improve control of batch manufacturing plants.
• Can be applied regardless of the degree of automation.

Flexible Batch Management

By using Flexible Batch Management technology - based on the ISA-88 Process Model - the plant’s equipment and processing capabilities as well as its control and information requirements are defined. Once defined, recipes can be easily created, scheduled and executed. This allows the following to be readily achieved:

• Comprehensive batch execution and equipment history with full material genealogy
• Reconciliation of material inventory with actual quantities in vessels.
• Use of material characteristics during the batch process, including the ability to dynamically adjust and apply formula parameters at runtime.
• Generation of specific alarms associated with a specific batch.
• Automated batch report creation; for example, at the end of each batch.
• Generation of Electronic Records which satisfy the requirements of 21 CFR Part 11.

Our Flexible Batch Management technology aims to yield the following benefits:

• Reduced manufacturing costs.
• Faster time-to-market and enhanced productivity.
• Increased product quality.
• Improved compliance and governance.

Meeting Key Batch Control Requirements

Our ISA-88 based technology enables EmsPT to meet key Batch Control requirements such as:

Scalability - Scalable architecture to meet the needs of small, simple applications such as pilot operations, all the way up to extremely large and demanding systems.

Flexibility - The ability to quickly and easily add additional processing lines, manufacturing cells or operator nodes, and provides remote development capabilities in a very simple, straightforward manner.

High Availability - In many critical batch applications, a PC hardware failure cannot be tolerated. To avoid such failures, the use of redundant or high availability hardware facilitates are deployed. Use of virtualization technologies also offer opportunities to lower hardware costs, achieve greater performance, and enable high availability and protection against disasters.

Clients – Comprehensive user friendly Client interface to the Batch Control system.

Connectivity - Connectivity to any control system or plant floor device, or external databases, enabling end to end production information management.