Advanced Batch Management Solutions

For Specialty Chemicals, Pharma, Food & Bev, Consumer Packages Goods

Supertech offers cost effective Batch Management Solutions built around Schneider Electric EcoStruxure Hybrid DCS, a new generation DCS designed specifically to meet the automation requirements of Hybrid industries like Specialty Chemicals, Pharma (API), Food & Beverages and Consumer Packaged Goods. Most of the processes in these segments are batch processes or a combination of batch and continuous processes. The DCS comes with a library of templates suitable for both batch and continuous process applications. While the DCS is scalable from approx. 200 I/O to 20000 I/O, Supertech offers three levels of Batch Management solutions which can be integrated with the Hybrid DCS.

1. The Sequencer Template

A simple recipe based batch operation within the DCS can be achieved with the Sequencer Template. The sequence of operations can be carried out in either auto mode or manual mode.The template is designed for processes sequence up to 64 steps and 5 parameters control. The Individual steps progress from one step to the other consecutive step depending upon the predefined logic conditions. The template provides informative and operator friendly sequence control with operator guide message feature.

For more information on the Sequencer Template, 30 days free trial or purchase, please visit Schneider Electric Exchange on the following link:
Link: https://shop.exchange.se.com/en-US/apps/52223/hybrid-dcs-template-library—sequencer-for-batch-processes/overview

2. SUPERBatch – ISA S88 based Batch Management Software

SUPERBatch is developed indigenously by Supertech based on their long experience in automating batch processes. It is a proven and cost-effective solution based on ISA S88 Batch Standard and can be used for both simple and complex batch operation. It consists of five modules – Plant Editor, Recipe Engine, Batch Scheduler, Batch Execution and Report viewer. It provides flexible, recipe-based semi or fully automated batch process operation. After every batch, reports for batch log, raw material consumption, quality parameters, energy consumption etc. are automatically generated. The batch data is stored in MS SQL Server database. Apart from the standard batch reports, batch to batch comparison of performance with the golden batch for defined KPIs such as batch cycle time, raw material consumption, energy consumption, quality parameters etc. are available. For advanced reporting MES is used along with Batch Management System. The Batch Management System can also be integrated with ERP system. SUPERBatch helps in achieving consistency in the batch operation, uniform product quality, minimize wastage and energy consumption, create authentic tamper-proof records for statutory compliance, eliminate human error and provide on-line data for managing the inventory, supply chain and production schedules.

For more information on SUPERBatch, 30 days free trial or purchase, please Schneider Electric Exchange on the following link:
Link: https://shop.exchange.se.com/en-US/apps/60517/superbatch—isa-s88-based-batch-management-software

3. Wonderware® InBatch

InBatch is control system independent batch management software from Aveva (Schneider Electric) that can be used for the most complex batching processes that require a high level of flexibility. Equipped with easy-to-use recipe configuration tools, process engineers can quickly create or change recipe procedures and formulas without requiring any expertise in the underlying control systems. InBatch’s uniqueness is in its process capabilities model, which goes beyond ISA-88 to include transfer phases. This enables the batch engine to manage flexible product paths, allowing simultaneous multi-product and multi-stream batch execution on shared equipment. Built-in security and material management capabilities including material consumption, movements and inventory levels contribute to a comprehensive Electronic Batch Record (EBR) and reduce the cost to comply with industry regulations.

For more information on Wonderware InBatch, please click on the following link:
Link: https://www.wonderware.com/manufacturing-operations-management/inbatch/
 

Some of the successful Batch Process Automation installations by Supertech in last two years are as follows:

S. N. Name of Customer Location Application Batch Engine
1 Kansai Nerolac Paints Jainpur, U.P. Water Based Paint InBatch
2 Kansai Nerolac Paints Hosur, Tamilnadu Emulsion SUPERBatch
3 Berger Paints Goa Emulsion Sequencer
4 Berger Paints Jejuri, Maharashtra Industrial Resins InBatch
5 JSW Paints Vijayanagar, Karnataka Water Based Paints InBatch
6 JSW Paints Vasind, Maharashtra Industrial Paints InBatch
7 Pidilite Industries Vapi, Gujarat Adhesives SUPERBatch
8 Clean Science & Technology Kurkumbh, Maharashtra Specialty Chemicals Sequencer
9 Polychem Resins Dubai Industrial Resins SUPERBatch
10 Aypols Polymers Coimbatore, Tamilnadu Industrial Resins SUPERBatch
11 IVP Industries Tarapur, Maharashtra Industrial Resins SUPERBatch
12 U.K. Paints Sikandrabad, U.P. Emulsion SUPERBatch