- Do you need to automate or re-automate your Batch process? - Are you looking for easy Recipe creation and flexible batch manufacturing? - Are you aware of ISA-88? - Do you need material genealogy reports to meet International food/drugs manufacturing regulations such as FDA? - Do you wish to use Electronic Signatures as part of your Batch manufacturing processes? The Webinar is designed to introduce you to the Wonderware InBatch Flexible Batch Management system. Webinar Content: Positioning Integration with Wonderware Overview of Modules Process Modelling Material Management Recipes Batch Management Batch History & Batch Reporting System Architecture Summary

1. Wonderware Interactive Webinar Series
Helping you see more clearly
InBatch - Flexible Batch Management
Geoff Brown
Senior Consultant

2. Agenda
► InBatch - Flexible Batch Management
▪ Positioning
▪ Integration with Wonderware
▪ Overview of Modules
▪ Process Modelling
▪ Material Management
▪ Recipes
▪ Batch Management
▪ Batch History & Batch Reporting
▪ System Architecture
▪ Summary

3. What is InBatch?
► InBatch is Flexible Batch Management
software designed to model and automate
batch processes.
▪ Consistent with S88
(IEC 61512 & ANSI/ISA–88.01 – 1995 Batch
Control Part 1: Models and Terminology)
▪ Model-based
▪ Easy recipe creation
▪ “Out-of-the-box” batch simulation
▪ Comprehensive production history
▪ Material genealogy

4. The InBatch Value Proposition
► InBatch's powerful batch execution engine
(combined with its integration with the other
Wonderware components)
significantly reduces the cost and time to
implement your batch processes.

5. Benefits of InBatch Premier
► Reduce the Life-Cycle Engineering Effort
▪ Top down design
▪ Material Unit-to-unit transfers
▪ Re-useable phase block libraries
▪ Sustainable control code
▪ Less dependence on system experts
▪ Built-in batch simulation

6. Competitive Benefits
► Faster Time-to-Market
▪ Production flexibility
▪ Graphical recipe creation
▪ Performed by non-engineering personnel
▪ Centralized recipe management
▪ Simulate new recipes
▪ Identify scaling and equipment issues
▪ No impact on control code
▪ Eliminate re-validation of the process

7. Production Flexibility and
Tracking
► Recipe procedure changes
► Material formulation changes
► React to unexpected changes
► Complete material genealogy
▪ International Food Standard (IFS), European
Union (EU)
▪ Bio-terrorism
► Electronic Batch Record
▪ 21 CFR Part 11

8. Integration with Wonderware
ArchestrA
► InTouch
▪ Configurable Operator Interface which can
show Process and Batch information
► Wonderware Historian
▪ Common MSSQL history database
▪ Comprehensive process reports
► Wonderware Information Server
▪ Current and Historical Reports
► Wonderware Application Server
▪ Complex Phase scripting
▪ Object Library Available

9. InBatch Premier Extensibility
► ActiveX Controls
► OLE Automation Servers
► Standard, Open History Database
► Connectivity with plant floor
► ERP integration
► Finite scheduling integration

10. Overview of Modules
► Process Model
▪ Represents a complex batch process in terms
of its processing capability without any
reference to hardware.
► Materials Management System
▪ Materials database used to track where
materials are stored and in the construction
and execution of recipes.

11. Overview of Modules
► Recipe Management System
▪ Graphical recipe development system for
creating and sustaining product Master
Recipes. Recipes are both equipment and
path independent.
► Batch Management System
▪ Manages the process equipment and
orchestrates the execution of the phases
within a recipe procedure.

12. Overview of Modules
► History Database
▪ MSSQL open, relational platform for storing all
batch processing activity including process
data, material genealogy, alarms, operator
events, comments, etc.
► Reporting System
▪ Integrated reporting system using Wonderware
Information Server.

13. Overview of Modules
► Security System (option)
▪ 21CFRpart 11 compliant configurable
application and function based security
environment
▪ Operating System Security
► InTouch HMI System
▪ Integration with InTouch as the operator
interface including ActiveX objects, and
automatic alarm and event storage.
► Connection to Plant
▪ SuiteLink Family of DA and I/O Servers
▪ Wonderware Application Server

14. Process Modelling -
Define Units
Bulk Bulk
Storage 1 Storage 2
A Unit is an equipment
Reactor 1 Reactor 2
entity that holds,
processes or packages
materials.
Hold Hold
Tank 1 Tank 2

15. Process Modelling –
Define Connections
Bulk Bulk
Storage 1 Storage 2
A Connection defines a group
of equipment that facilitates
the movement of materials
Reactor 2
Reactor 1
from a source unit to a
destination unit.
Hold Hold
Tank 1 Tank 2

16. Process Modelling –
Group Units into Process Classes
Bulk Bulk
Storage 1 Storage 2 Bulk Tanks
A Process Class is
a group of units
that have the same
Reactor 1 Reactor 2
Reactors processing
capabilities or
perform the same
functions.
Hold Hold Hold Tanks
Tank 1 Tank 2

17. Process Modelling –
Define Phases and Parameters
Bulk Bulk
Storage 1 Storage 2
Process Class: Reactors
Phases with Parameters:
Reactor 1 Reactor 2
Heat Temp
Reactors Cool Temp
Soak Temp, Time
Agitate Speed, Time
ManualAdd Quantity
Hold Hold
Tank 1 Tank 2

18. Phase Logic
Formula Parameters
Interlocks ► Most commonly found
implemented in the PLC, DCS or
Phase Control Phase Status
soft PLC.
Ready ► Required for each process and
Start
Run
connection phase.
Hold ► Modular, easy to maintain and
Held re-use.
Restart Phase Logic
Abort
Done ► Complex “Soft Phases” can be
Aborted readily implemented within
Reset Wonderware Application Server
Interlocked
Control Inputs
Control
Outputs

19. Materials Management
► Provides for the definition and tracking of
all batch materials including:
▪ Ingredients, Intermediates, Finished Goods,
and By-products
▪ Material Characteristics
▪ Material Location Assignments
▪ Material Tracking Information

20. Master Recipe
Header Equipment
Formula Recipe Procedure

22. Batch Management System -
the Batch Engine
► Schedule Dispatching
► Batch Initialization
► Batch Modes
▪ Automatic, Semi-Automatic, Manual
► Equipment Arbitration
▪ Automatic, Recipe, Manual
► Batch Execution

23. Batch Execution
► Dynamically transform a Master Recipe
(Equipment Independent) into a Control
Recipe (Equipment Dependent).
► Orchestrates running of Phases.
► Allocates and Releases Equipment based
on:
▪ Is the Equipment Specified in the Train?
▪ Unit Attributes (Capacity, etc.)
▪ Equipment Status (Clean, Dirty, etc.)
▪ Equipment State (Ready, Run, Held, Alarm)
▪ Equipment Availability

24. Batch History
Batch
Reporting
Equipment Equipment Usage Via WEB
Using WIS
Phase
Materials Used
Phase
Materials Produced
Phase
Alarms
Phase
MSSQL
Operator Changes
Phase
Trend Data

25. Batch Reporting from MSSQL
► Integrated Reporting System
▪ Implemented using Microsoft Reporting Services as
part of Wonderware Information Server (WIS)
▪ Web reports via Internet Explorer
▪ Real-Time Reporting
• End of Batch Reports, Time Triggers, etc.
• Combines Batch and Continuous Data
▪ Off-Line Reporting
• Historical Data Retrieved via pre-defined reports
▪ Open MSSQL Database for third-party data retrieval
and reporting applications

26. InBatch 9.0 – Reporting
► Report Execution
▪ All pre version 9.0 reports are available
through Reporting Services & WIS

27. InBatch 9.0 – Reporting -
Examples

28. InBatch 9.0 – Reporting -
Examples

29. InBatch 9.0 – Reporting -
Examples

30. System Architecture –
from Small ..
InBatch Server
MSSQL Server & WIS
InTouch Runtime
I/O Server
Phase Logic

31. System Architecture ..
To Large Redundant
InBatch
Servers Historian WIS
Dual
Redundant
Pair
InTouch/InBatch Runtime Clients Office Clients
I/O Servers or
Application Object
Servers
PLC Network
Phase Logic

32. InBatch 9.0 integrated with
System Platform
Extremely flexible and powerful batch
management capabilities
InBatch Server MX communication Phases modelled
within Control System
PHASE 4 PHASE 1
PHASE 5 PHASE 2
Device Integration Device
PHASE 6 System PHASE 3
Platform
Extremely flexible and powerful
Phases modelled platform and plant model
within System
Platform

33. InBatch Summary
► Complete, integrated robust batch execution
system
► Reduces life-cycle costs for batch applications by
40% - 60%
► Provides complete material genealogy
► Provides a comprehensive production history
► Security available that exceeds the most
demanding requirements
► Reduces or eliminates custom integration
requirements.
► A top-down approach that creates a sustainable
solution that responds to change.

34. Powering intelligent plant
decisions in real time.

35. FDA 21 CFR Part 11
► Electronic Records; Electronic Signatures
► Important Date: August 20th, 1997
► Affects Pharmaceutical & Biotechnology

36. 21CFRpart 11 Major Areas
► Data Integrity
▪ Audit Trail
► Application Security
▪ Application Functionality
• Segment functionality, Auto-Logoff
▪ User Identification
• 2 Components Required
▪ Password Management
• Password aging, uniqueness, account disabling, minimum
characters

37. InBatch and 21 CFR Part 11
1995 InBatch Security Manager developed in
coordination with customers in the food
and pharmaceutical industries.
1996 InBatch 4.0 introduced.
1997 FDA approves 21 CFR Part 11
InBatch was already consistent with
the regulation !!!

38. InBatch 9.0 Security (2009)
4.0 (1996)

39. InBatch Security Features
► Links activity to electronic Signature
► Provides Audit Trail
► Uses both traditional “Log In” security and
Transactional security
▪ Prevents unauthorized access
▪ Functions can be configured to require up
to 2 electronic signatures

40. Data Integrity
► Transactional Data – Protect using
facilities of MSSQL
▪ Alarms & Events
▪ InBatch Electronic Batch Records
► Continuous Time-stamped data
▪ Wonderware Historian (InSQL) data cannot be
manipulated.
▪ Protect files using Windows Security

41. Summary
► InBatch Premier Edition
▪ Flexible Batch Management System
▪ Functionally rich
▪ ISA S88 consistent
► 21CFRpart11 Compliant

42. An InBatch success story
British Bakels - Bicester

43. British Bakels
British Bakels, Bicester, is a leading supplier
of baking ingredients. They operate from
modern production facilities and offer high
service levels to commercial bakeries and
other food manufacturers.
Bakels required a system that would simplify
the production of hundreds of products whilst
providing consistent quality; they chose
Wonderware’s InBatch® system which was
deployed by Stratos Control Systems Ltd.

44. Situation, and finding a solution
► Bakels has invested in equipment, tools and training that allow continuous
business growth to be achieved.
► To provide smooth and effective operation it was foreseen that the company
would need a solution that could flexibly handle the full permutation of recipes
and mixes that they needed to process.
► At first consideration was given to a wholly PLC based system but it soon
became clear that this was inappropriate to the scale of the problem.
► Bespoke computer solutions were also dismissed as being an unacceptable
business risk.
► Stratos proposed a far more powerful and standard solution centred upon
Wonderware’s InBatch system, following evaluation this was adopted.
Located on a 5.5 acre site in Bicester, Bakels has invested over £15m in powder blending
and wet production, and in warehousing. Production volumes exceed 20,000 tonnes.

45. InBatch in use
► The use of Wonderware’s InBatch is part of a comprehensive scheme that
automates the entire business process.
► The company’s manufacturing plan is held with a Microsoft® Dynamics
Axapta MRP system which produces a daily schedule, the end result of
which is pallets loaded with the required dry basic ingredients for the day’s
production, wet ingredients being pumped automatically.
► The InBatch system takes this schedule information and produces step by
step production instructions for operators and automation controllers.
► The process involves weighing, mixing, dosing, blending using a carefully
controlled sequence of vessels for melting, dissolving, mixing and
cooking.
► The many combinations of ingredients to make Bakels’ products are in this
way easily handled without error and with the ability to produce high daily
volumes from many differing orders.
► Production at Bakels is arranged in lines, each having flexible operation and
capacity to meet differing production demands.
► CIP is built in to the system and is also under full automatic control. .

46. Dosing, mixing, blending...

47. InBatch in action...

48. InBatch in action...

49. Doing the work...
► The development of the system was done jointly by Bakels’ and Stratos’
engineers, with assistance in the Batch Management consultancy by
Wonderware batch specialist Dr Geoff Brown.
► The architecture of the system involves dual server redundancy, Ethernet and
wash-down touch screens on the plant itself.
► The system allows both manual and automatic operation and quickly gained
operator acceptance following in-house training.
Away from all this activity is Bakels’ product development laboratories, here new
recipes are developed both speculatively and also at the request of bakers. Once
developed, the production method has to be scaled up to deliver the same
characteristics in volume manufacture.
Products are formulated to suit each market sector and British Bakels has teams that
focus on serving the particular needs of each sector. Bakels’ operation is BRC level “A”
accredited (which was the subject of a recent audit by EFSIS that they passed with
“flying colours”) and the company has further accreditation as a Halal Food Authority
approved supplier and by The Soil Association, as producer of organic products.

50. Quotable...
Nick Luxemburg, Bakels’ Engineering Manager said,
“The system that has been installed provides us with
major competitive advantage and the ability to deliver
right on schedule”...
“What we have achieved is Consistent Quality”
www.bakels.co.uk
The company has defined
expansion plans to establish further
lines within the same production
area to support planned business
growth, the efficiency and flexibility
of the batching system contributing
to the basis for the business model
for this investment.

51. Success Stories
This case study and many others
can be found at...
http://www.wonderware.co.uk/success-stories/

52. Forthcoming...
► Thin Clients:
▪ 13th January 2010
► InTouch HMI:
▪ 26th January 2010
► InTouch CE (SI’s only):
▪ 10th February 2010

53. Questions?

54. Powering intelligent plant
decisions in real time.