Batch Process Control
Master your batch processes, ensure scalability and repeatability, and protect your critical production runs.
Advanced batch control with automation, recipe management, and SCADA built on ISA-88 standards.
Your Challenges
Batch processes are at the heart of many industries (pharmaceuticals, chemicals, petrochemicals, cosmetics, food & beverage…). Their complexity lies in sequencing phases, managing recipes, and controlling process parameters.
Common pain points :
- Highly complex recipes (multi-step, multi-parameter)
- Difficulty ensuring batch-to-batch repeatability
- Mandatory traceability of operations and parameters (GMP, regulatory)
- Heavy reliance on operators
- Risk of sequence errors (dosing, timing, temperatures…)
- Difficulty optimizing cycle times
- Evolving recipes
- The result : product variability, nonconformances, lost productivity, and regulatory risk.
Our Solution
At ISII-Tech, we deploy end-to-end batch control solutions that combine automation, recipe management, and advanced SCADA.
Our goal : production that is reliable, repeatable, traceable, and scalable.
Recipe Management
- Creation and management of industrial recipes
- Step parameter settings (temperature, duration, speed…)
- Recipe versioning
- Validation and secure change control
- Recipes become centralized, controlled, and secure.
Batch Sequence Automation
- Automatic execution of phases :
- Charging
- Agitation
- Heating
- Cooling
- Transfer…
- Step sequencing with conditional logic
- Handling of interruptions, holds, and restarts
- Fewer operator errors and more reliable cycles.
Critical Operations Integration (Weighing / Dosing)
- Connection of weighing and dosing systems
- Real-time quantity verification
- Tolerance checks
- Traceability of material additions
- Ensures recipe accuracy and compliance.
Batch Monitoring
- Real-time tracking of batches in progress
- Visualization of steps and transitions
- Process parameter historization
- Campaign tracking dashboard
- UX-driven operator screens
- Operators get a clear, instant view.
Traceability & Compliance
- Complete recording of batch data :
- Parameters
- Operators
- Materials
- Equipment
- Batch report generation (batch records)
- Complete audit trail
- Essential for regulated environments (GMP, FDA).
Performance Optimization
- Cycle time analysis
- Identification of critical phases
- Reduced idle time
- Recipe optimization
- Improved productivity and yield.
System Integration
- MES connectivity (production tracking)
- ERP interface (work orders)
- Data historization (data analysis)
- Interoperability with SCADA and DCS
- Direct field connections
Technologies & Partners
AVEVA Batch Management
Siemens SIMATIC Batch
Industrial Weighing Integration
- Scale interfaces (Mettler Toledo, Sartorius, Minebea…)
- Direct ERP / MES / equipment connectivity
- Integration in GMP / pharma environments
Standards
- ISA-95 (ERP / MES)
- ISA-88 (batch & recipes)
- GMP / Data Integrity (ALCOA+)
Your Benefits
Structured batch control delivers :
Repeatable production
Fewer operator errors
Complete, compliant traceability
Recipe flexibility
Faster cycle times
Lower material losses
Case Studies
Case Study
Industrie pharmaceutiquePharmaceutical Industry
- Challenge : Secure weighing operations, ensure full lot traceability, and modernize operator interfaces with better ergonomics and digitalized processes
- Solution :
- Deployment of a SCADA architecture based on AVEVA System Platform and InTouch OMI
- Integration of AVEVA MES to manage production operations
- Connected weighing booths to make dispensing more reliable
- Digitalization of batch records
- Résults :
- Zero lost batches
- Fast recovery after incidents
- A far more reliable process