BatchingAdvanced Batch ControlBatch production is one of three main types of manufacturing processes, used to turn rawmate...
2 METTLER TOLEDO - White Paper - BatchingBatching2011©Mettler-Toledo AGAn example of batch control most people can relatet...
3 METTLER TOLEDO - White Paper - BatchingBatching2011©Mettler-Toledo AGExample of a multi-material, 2 speed feed automatic...
4 METTLER TOLEDO - White Paper - BatchingBatching2011©Mettler-Toledo AGAchieving Automated TargetsThe S88 standard outline...
5 METTLER TOLEDO - White Paper - BatchingBatching2011©Mettler-Toledo AGAuxiliary Equipment ManagementControl of auxiliary ...
6 METTLER TOLEDO - White Paper - BatchingBatching2011©Mettler-Toledo AGImplementing batch control management capabilitiesc...
BatchingMettler-Toledo AGCH-8606 GreifenseeSwitzerlandPhone	 +41 44 944 22 11Fax	 +41 44 944 30 60Subject to technical cha...
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Batch Control According to S88 Standards

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The ANSI/ISA-88 addresses manual and automatic batch process control by providing standards, terminology and procedures. It ensures consistent recipe sharing and data handling across multiple locations. A new white paper outlines how the application of S88 for stand-alone batch control minimizes engineering, training and compliance efforts.

An accurate, reliable weighing system that measures ingredients and transfers them into the batch is a critical part of the batching process. This process can be automated, manual or a blend of both. Ideally, automated transfer and batch control can be managed at the weigh terminal eliminating the need for a full-scale PLC control system. The right weigh terminal may also guide manual batching. A stand-alone batch control system may benefit smaller-scale operations because it eliminates the processing time and costs associated with PLC programming. It also minimizes efforts for engineering, training data tracking and tracing if it has incorporated S88 guidelines. Download here: http://ow.ly/ltzxF

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Batch Control According to S88 Standards

  1. 1. BatchingAdvanced Batch ControlBatch production is one of three main types of manufacturing processes, used to turn rawmaterials into finished goods. It can be defined as:• Starting with input materials• Subjecting them to an ordered set of processing activities• Creating a new output materialContents1 The need for dedicated batch control2 Batch control system selection considerations3 Implementing dedicated batch control4 Summary5 Additional resourcesAn accurate, reliable weighing system that measuresingredients and transfers them into the batch is a criti-cal part of the process. This process can be auto-mated, manual, or a blend of both.Realistically, automated transfer and batch control canbe managed at the weigh terminal instead of a full-scale PLC or DCS control system. The right weigh ter-minal/system can also guide manual batching. Astand-alone batch control system may be of particularbenefit in smaller-scale operations because it elimi-nates the processing time and cost associated withPLC programming.This paper will explore benefits of stand-alone batchcontrol and discuss ways they help:• Achieve consistent results• Increase efficiency• Lower costsUltimately, consistent results increase customer satis-faction and make it easier to meet processing or prod-uct certification standards. The right solution will giverise to process transparency while simultaneouslyimproving a company’s bottom line.
  2. 2. 2 METTLER TOLEDO - White Paper - BatchingBatching2011©Mettler-Toledo AGAn example of batch control most people can relateto is baking bread. Raw recipe materials are lined upthen combined in an ordered fashion. Tools such mea-suring spoons, mixers, and heat transform the rawmaterials into a new output material – a fresh, deli-cious loaf of bread.This example is simplified, but it translates to themanufacturing environment. Only now, imagine hun-dreds or even thousands of bread loaves being bakedevery day. There may even be variations in forms andflavors.The batch control scenario has changed significantly.A batch control solution to manage batch-to-batchconsistency is critical to ensure high product quality.Investment in a well-designed batch control system tomanage this larger-scale manufacturing scenario canalso help:• Increase throughput• Reduce raw materials waste• Eliminate end product variations• Maximize overall efficiency 1 The need for dedicated batch controlWhen faced with selecting the right batch controlsystem for a particular process, the task may seemdaunting: How can it be established that the selectedsystem will improve production efficiency, eliminateraw material losses, and improve output consistency?The overall solution must manage the various typesof material transfer onto the weigh platform and weigheach ingredient. A weigh terminal that can manageboth activities lends itself to batching applications andcan help a control engineer simplify processes, sinceingredient weighing and material transfer are essen-tially two parts of a single action.A PLC system can be applied effectively, particularly ininstances when the batch process is fixed – producingthe same end product – and does not see a great dealof switching between ingredients and recipes. How-ever, this may not be the best solution for the small tomid-size operation that requires flexibility in their pro-cess because of limited resources.The Instrument Society of America (ISA) S88 BatchControl (Part 1-4) provides a consistent batch stan-dard that can help manage the batch application, nomatter what kind of solution is chosen. Having a con-troller that has the S88 guidelines built in allows theuser to have a modular system that will provide a con-sistent application of the control system across mul-tiple locations, which can minimize training require-ments, simplify user interface and allow multi-plant in-stallations to share recipes and information about theirprocess in the same data structure. With a PLC solu-tion careful programming and implementation wouldbe required to ensure that a consistent approach wasfollowed, especially in multi-plant installations.A dedicated batch control solution, on the other hand,will combine batch management and material trans-fer technology into one, full-featured batch controller.This eliminates the need for PLC code writing, reducesstart-up time and allows the customer to focus on theirareas of expertise: their unique, palatable recipe. 2 Batch control system selection considerations
  3. 3. 3 METTLER TOLEDO - White Paper - BatchingBatching2011©Mettler-Toledo AGExample of a multi-material, 2 speed feed automatic material transfer Batch installationSelection of a dedicated system that follows a docu-mented structure for equipment handling, I/O control,and material paths/recipes in the production processcan produce immediate and measurable benefits.The ISA S88 batch standard provides a helpful guideto this selection by:• Defining a useful batch control model• Communicating common batch control requirements• Offering helpful configuration information• Guiding vendor solution integration The high-level objective of S88 is helping batch pro-ducers make consistent, repeatable batches. Thestandard provides common terminology for batchmanufacturing as well as guidelines on how to recoverfrom upsets during batch processes.Batch Control/Reliable WeighingHaving consistent guidelines at the center of a batchprocess can help lower production costs, increasethroughput, improve yield, reduce material loss, andincrease batch equipment utilization.Following the S88 standard separates the physicalequipment from the recipe. This allows flexibility insystem configuration and makes switchover time fromrecipe to recipe much shorter, which helps increasethroughput. The standard also provides an operatorwith a consistent interface, which helps increasefamiliarity with and utilization of the equipment. Material loss is minimized because the operator isprompted through each ingredient addition. A userinterface allows each material to be added within anallowable tolerance range.Ideally, a batch controller will take the S88 batch stan-dard into account out of the box to simplify batch con-trol implementation. A reliable weigh terminal such asIND780batch will also be integrated into the solution. 3 Implementing dedicated batch controlMaterial 3Material 2Material 1Fast FeedFine FeedFast FeedFine FeedFast FeedFine FeedFast FeedFine FeedFast FeedFine FeedMaterial 5Material 4Hand AddOperatorIND780batchTerminalMixerScaleDischarge MaterialTo storage tank
  4. 4. 4 METTLER TOLEDO - White Paper - BatchingBatching2011©Mettler-Toledo AGAchieving Automated TargetsThe S88 standard outlines a modular, flexible processthat allows a user to simplify a batch process. An inte-grated, stand-alone solution supports this flexibility bypre-defining the process equipment and letting the op-erator select from several different recipes, shorteningthe time to switch from batch to batch. It also providescentral control of material transfer using machinerysuch as feed valves, gates, and screw conveyors whilesimultaneously monitoring weight to ensure accuratetarget cutoff of each transferred material. This candramatically improve batch throughput and reducematerial waste. Manual Processes & Batch ControlIf the process is manual – with an operator selectingand adding ingredients – typically no discrete I/O isassociated with control. This method is highly flexiblesince there is no associated I/O and several differentmaterials can be batched without preconditions.In a manual process, the operator typically managesbatching. However, adding a batch control system toguide the operator can eliminate problems with over-and under-filling and ensure that unnecessary ingredi-ents are not added or necessary ones missed.Generally, the operator will use a bar code scanner toidentify an ingredient, add it, and move on to the next.Material validation alerts the operator when an incor-rect material is chosen and provides a prompt to scanfor the correct ingredient to ensure batch consistency.In a blended approach, the operator may start a batch.Then, the rest of the process runs without user inter-vention unless additional hand-added ingredients areneeded.If the process includes automatic material transfers,then a batch controller that allows assigning I/O tomanage the material feeds is required. Usually, thereare also auxiliary equipment pieces that require man-agement.Barcode Scannerfacilitates tracking andtraceabilityIND780batchTerminalguides operatorthrough recipe withon-screen promptsHand Addup to 999 materialsper recipeBench ScaleExample of a multi-material, manual formulation Batch installation
  5. 5. 5 METTLER TOLEDO - White Paper - BatchingBatching2011©Mettler-Toledo AGAuxiliary Equipment ManagementControl of auxiliary equipment may require certaincriteria to operate properly. For example, if a mixer isrequired, the batch controller may need to be able to:• Turn on the mixer at a specific recipe step• Pulse the mixer for a certain amount of time• Delay starting the mixer until an add-by-hand ingre-dient is placed on the scale before the mix startsNo matter the type of batch control being used, acontroller that accurately handles material transfers,provides accurate target cutoffs, minimizes overfeed/underfeed scenarios, and manages the batch processis required for batch-to-batch consistency.Track and Trace/Data CollectionAnother desirable element for a batch controller is theability to track and trace phases in the batch processto identify:• When a product was made• What and how much material was used• Which operator ran the particular batchThis allows investigation into potential performanceproblems. Managers can check for evidence of pro-duction changes. This helps with easy batch and rawmaterial identification and can help:• Determine why a batch may have been “off,”• Pinpoint the ingredient that caused the problem• Minimize number and extent of recalls• Allow users to approach vendors who supplied theingredientA stand-alone batch control processor should be ableto incorporate track-and-trace functionality, as well ashandle recipe creation and storage, backup terminalsettings and collect data. These actions are to:• Implement a defined recipe-creation sequence• Edit ingredients or amounts• Re-scale the entire batchUsing a dedicated, stand-alone batch control solutionthat accommodates the above functionalities can sig-nificantly improve batch repeatability and productivitywhile controlling costs. METTLER TOLEDO offers thistype of robust functionality in various stand-alone andeasy to integrate batch controllers.PC configuration tool for Batch applicationallows off-line recipe creation and systemconfiguration.
  6. 6. 6 METTLER TOLEDO - White Paper - BatchingBatching2011©Mettler-Toledo AGImplementing batch control management capabilitiescan help achieve advanced material transfer and pro-cess control goals. Using an out-of-the-box solutionthat integrates weighing and material transfer can pro-vide powerful cost and time savings for smaller-scaleproducers who may not have the resources to imple-ment a PLC with its requisite programming expertiseand time.Ideally, any chosen solution will:• Provide dedicated batch control for both manual andautomatic batching• Contain control logic in the measurement instrumentfor faster I/O• Adhere to the S88 batch standard for process flex-ibility and quality maintenance• Increase material transfer throughput and improvefeed accuracy• Provide track and trace/data collection to managerisk and minimize wasteThe right stand-alone solution can run multiple batchprocesses while eliminating complex PLC reconfigura-tion when a customer’s needs change. The resultingtighter control can make products more consistent. Thiscan increase customer satisfaction and loyalty while si-multaneously improving productivity and enhancing thebottom line. 4 SummaryThe following links and papers can provide more information on industrial weighing solutions and how effectivebatch control can enhance quality, improve materials use rates, and lower production costs.• METTER TOLEDO Material Transfer Controlwww.mt.com/qi• Instrument Society of Americawww.isa.org• Applying S88, Batch Control from a User’s perspective; Jim Parshall and Larry Lamb – ISBN #1-55617-703-8• Batch Control Systems, Design, Application, and Implementation 2nd Edition; William Hawkins and Thomas Fisher – ISBN # 1-55617-967-7• Control Globalwww.controlglobal.com• Functions that need to be considered in for Material Feed (Transfer) Batch Controls; Charlie Fu Ph.D, Technology Leader, Procter & Gamble• World Batch Forumwww.wbf.org• ARC Advisory Groupwww.arcweb.com 5 Additional resources
  7. 7. BatchingMettler-Toledo AGCH-8606 GreifenseeSwitzerlandPhone +41 44 944 22 11Fax +41 44 944 30 60Subject to technical changes© 08/2011 Mettler-Toledo AGMarCom IndustrialFor more informationwww.mt.com/ind-food-productivity-guide2

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