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Batch Automation

with resource allocation, recipe management, and real-time monitoring for protective and reactive washcoats, additive manufacturing inks, ionomers, paints, glues, broths, titania, and resins.

Beyond the ISA-88 batching standard

ISA-88 batching standard provides standard models and terminology for defining the control requirements for batch manufacturing plants. Our solutions adhere to the ISA-88 standard while incorporating bespoke control algorithms and adaptive dosing tailored to each customer's specific needs. We have years of experience developing process control and each project is an opportunity to improve processes while respecting material, space, and budget constraints. This ensures not only compliance but also optimization for material efficiency, flexibility, and minimal waste.

Holistic project approach and flexibility

We offer end-to-end solutions, including consulting, designing, improving, and maintaining batch processing systems using industry-leading batch management software. Our services cover both software and hardware integration, ensuring a seamless and efficient automation environment. Emphasizing knowledge transfer and operator training, we ensure that operators are well-prepared to manage the new systems effectively. Our experienced engineers provide first-line support, addressing any issues quickly and effectively.

Optimized workflow and resource management

Unit allocation functionality prevents simultaneous usage of single units in different recipes, optimizing workflow and providing clear visibility of unit availability. This ensures efficient recipe selection and overall process management. We support the setup of redundant systems with primary and secondary batch management servers for minimal downtime in case of server failure and an enhancement in overall system reliability. We integrate the system seamlessly with MES and ERP so material is properly accounted for, and resources are managed rationally and efficiently.
BASF
Helios
IKA
Johnson Matthey
PPG

Automation of batch
production processes

A typical batching system is composed of components which include raw material feeders, mixers, reactors, storage tanks, pumps, valves, sensors, and control systems. Each component plays a critical role in the process, from the initial input of raw materials to the final output of the finished product. Such products include washcoats for catalytic clean air solutions; inks and ionomers for additive manufacturing, coatings for methane to hydrogen reformers, as well as a host of other chemical products, such as paints, glues, broths, titania, and resins.

We use batching software, such as AVEVA Batch Management, Rockwell Automation PlantPAx Batch, and Siemens PCS7 with SIMATIC BATCH, to automate these hardware components and integrate them into a cohesive system. Through the software, we control the timing, sequence, and conditions under which each operation occurs. Our solutions manage recipe parameters, allocate resources, and monitor the status of each batch, ensuring that all steps are executed correctly and consistently. By providing real-time data and feedback, well-integrated batching software helps operators make informed decisions, optimize performance, and maintain quality control throughout the production cycle.

Wc Vats 1

Batch Flowchart

Improvements on the ISA-88
batching standard

The ISA-88 standard provides a framework for standardizing terminology and processes in batching. This standard supports improved communication and interoperability between different components and systems. While adhering to ISA-88, our approach goes beyond by incorporating specialized improvements, such as control algorithms and adaptive dosing, tailored to the specific needs of each customer. We ensure that the batching system is not only compliant but also optimized for material efficiency, flexibility, and minimal waste. Our holistic integration of both software and hardware, combined with thorough simulation and operator training, guarantees the highest levels of efficiency and reliability in batch manufacturing processes.

Our proficiency in both software and hardware integration, including supportive systems such machine building, communication, and SCADA/HMI, ensures that we can deliver cohesive and efficient automation environments. We work closely with our customers throughout the entire journey, from initial consultation to system design, implementation, and ongoing support.

Batch automation
project step by step

Starting with a detailed plan involving specifications and recipes from the customer, we set up the batch management model and link tags, creating a digital blueprint for the process. We then develop simple testing recipes to ensure the system functions correctly, followed by more complex production recipes. These recipes are initially tested on simulation processes, allowing us to identify and resolve any issues before moving to real equipment in the plant. This approach minimizes downtime, makes sure no expensive materials are wasted in testing, and ensures a seamless transition from design to production.

Our unit allocation functionality further enhances efficiency by preventing simultaneous usage of single units in different recipes. This not only optimizes workflow but also provides clear visibility of unit availability for recipe selection. Additionally, we support and advise for the option to set up redundant systems with primary (master) and secondary (backup) batch management servers, ensuring minimal downtime in case of server failure.

Batch Screen 1 Zaslon

Batch Control Loop

End-to-end solution for
batch automation

We provide end-to-end solutions that include consulting, designing, improving, and maintaining batch processing systems. We handle both projects that focus solely on integrating batching software and comprehensive projects that include hardware integration, mechanical design, and machine building. This includes the installation and configuration of pumps, valves, and agitators, as well as supporting systems like conveyor belts and labelling stations. Our holistic approach ensures that all aspects of the automation system work together seamlessly.

We emphasize knowledge transfer and operator training, ensuring that the team of operators is well-prepared to manage and operate the new systems effectively. Our transparent deployment approach makes sure that operators are involved in the system from day one and receive more than just the bare minimum knowledge to operate system but understand how it functions better.

AVEVA
Batch Management

It offers a robust solution for complex batch processes, providing high flexibility and precise control. Its recipe management capabilities adhere to ISA-88 standards, featuring hierarchical and graphical tools for creating and managing recipes. Real-time monitoring ensures precise control and adjustment during batch execution, while comprehensive regulatory compliance features, including detailed audit trails and electronic signatures, meet stringent industry requirements. We have a diverse team of engineers certified in AVEVA software, additionally including SCADA, HMI, and MES.

Rockwell
PlantPAx Batch

It is part of the broader PlantPAx Distributed Control System (DCS), offering scalability from small to large batch operations. It integrates seamlessly with Rockwell’s Logix controllers and FactoryTalk suite, providing unified control and data analysis. The system supports complex batch sequences and multi-unit operations, enhancing operational efficiency and scalability. This combines well with our years of expertise in Rockwell and Allen-Bradley controllers which are meant to work together best in a Rockwell ecosystem, every part of which we are intimately familiar with.

Siemens PCS7
with SIMATIC BATCH

It provides a modular and scalable architecture, suitable for various batch processing needs. The system supports advanced batch control capabilities and complex recipes, with detailed monitoring and reporting tools. Its seamless integration with Siemens hardware and software ensures compliance and efficient process management, making it an ideal choice for industries requiring high flexibility and precision. We are certified in Siemens software and hardware, which our customers often require as standard in their manufacturing plants.

Related Solutions

Ink Preparation

Precise addition, dispersion, and heat treatment of inks for additive manufacturing, integrated into the production environment. Custom-designed vacuum and pump systems, tank inertization, and constant material tracking are just some of the improvements we made to this ISA-88 compliant process.

Washcoat Preparation

Catalytic washcoat preparation features precise dosing and phase control, real-time monitoring, and material traceability focuses on consistent individual batch quality. The ISA-88 compliant and improved process can be vertically and horizontally integrated into the wider production environment.

SCADA Solutions

Unified industrial software platform offers real-time management, visualization, analytics, and control across thousands of mobile touchpoints. Essential for industrial control and monitoring, it enables efficient operation, real-time oversight, and detailed analysis of complex, dispersed processes.

Chemical Processes

Comprehensive, automated, and ISA-88 compliant software and hardware solutions for the synthesis of resin, nanomaterials, preparation and addition of reactants, neutralization, pH regulation, peptization, pigmentation, crystallization, and production of PVA glue.

Data Historian

Specialized software system designed to acquire, store, process, and display real-time data from industrial equipment and processes, providing a centralized repository for time-stamped production data, machine performance metrics, and environmental conditions.

Frequently Asked Questions

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.

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