Batch management is the process of producing products in set quantities, known as batches, through a precise sequence of operations. It utilizes specialized software and hardware to control and monitor each stage of production, ensuring that every batch meets specific quality and consistency standards.
Batch management is important because it ensures consistency and quality in production, optimizes resource utilization, and minimizes waste. By providing real-time data and feedback, it allows operators to make informed decisions, improve performance, and maintain stringent quality control throughout the production cycle. This is essential in industries like chemicals, pharmaceuticals, and food and beverage, where precise production and regulatory compliance are critical.
The ISA-88 (IEC 61512) batching standard is a globally recognized framework for batch process control. This standard, also known as S88, provides a consistent model for designing, operating, and managing batch processes. It helps ensure repeatability, scalability, and quality across various applications.
Using the ISA-88 standard, we can break down the washcoat preparation process into smaller, manageable steps or "phases." Each phase represents a specific action or set of actions needed to complete a part of the process, such as filling a tank, mixing, heating, or dosing. By structuring the process this way, we can precisely control and monitor each stage, ensuring that the final product meets exact specifications.
We use and specialize in AVEVA Batch Management, Rockwell Automation PlantPAx Batch, and Siemens PCS7 with SIMATIC BATCH. Each of these software solutions offers robust capabilities for complex batch processes, including recipe management, real-time monitoring, and regulatory compliance. Our expertise in these platforms ensures precise control, scalability, and seamless integration with the respective hardware and software ecosystems.
INEA has experience in the batch management of a wide range of materials, including catalytic washcoats for clean air solutions, inks and ionomers for additive manufacturing, paints and coatings, machine lubricants, ceramics, polymers, liquid emulsions, suspensions, gels, and slurries. These materials are used across various industries such as chemical, pharmaceutical, and plastics. Our expertise covers the automation of processes involved in dosing, mixing, milling, and measuring, essential for producing these diverse products.
Simulation plays a crucial role in testing batch management systems by creating a virtual environment that replicates real-world production processes. This allows for thorough testing and validation of recipes, control sequences, and system functionality without the risk of disrupting actual production or wasting materials.
Through simulation, potential issues can be identified and resolved before the system is implemented on real equipment, minimizing downtime, and ensuring a smoother transition from design to production. It also provides an opportunity for operators to train on the system in a risk-free setting, enhancing their readiness and confidence in managing the actual batch processes.