Topic 1.1.4: Flexible Batch

  • What is flexible batch?
    • Equipment Independent Recipes.
    • Recipe Procedures are easily changed.
    • Materials can change locations.
    • Flexible Process Lines (Trains).
    • Lot Tracking.
    • Batch History.
  • The Batch Control System performs flexible batch through the:
    • Modeling the Process.
    • Recipe Management.
    • Batch Management.
  • How does the Batch Control System manage Batch Management?
    • Batch Management consists of scheduling, initializing, coordinating the execution of batches with the control system,  interfacing with operators and storing all batch activity.
    • These functions are provided by the Batch Manager, Batch Scheduler, and Batch Display programs. The final result is a flexible, reliable and intuitive approach to management of batch processes.
    • Batch Management coordinates the usage of process equipment for each batch. Each batch is a separate entity and contends along with other batches to own the process equipment it needs.
    • The Batch Manager assigns (Allocates) ownership of equipment to batches as equipment becomes available, and gives up (Releases) equipment when the batch no longer requires the equipment.
    • Flexible batch systems using PLCs and/or DCS controllers for control must take the approach, where the supervisory workstation is an active participant in executing a batch.
    • The reason for this is that unit management is very sophisticated in a flexible batch system. Most controllers do not have the ability to program a unit manager capable of interpreting and executing the recipe procedures available in the batch control system.
  • Flexible Recipes and Process Lines
    • In the batch control system, recipe procedures can be changed and new formula and process lines can be easily re-configured (not re-engineered) for new product introductions.
    • The batch system is flexible because it lets you model your plant, create new process lines, manage new recipes, schedule and execute batches, and keep a history of all batch processing activities.
Last modified: Tuesday, 28 April 2020, 11:33 AM