Flexbatch ISA 88 Batch and Recipe Management software

The Recipe is the Program

FlexBatch-Shortest-Batch

Develop, Modify and Document Recipes Without Technical Staff

FlexBatch® integrates recipe management and the automation layer so operators can quickly and easily develop, scale up, modify and schedule batch manufacturing recipes for products ranging from beer to chocolate to specialty chemicals and more.  FlexBatch delivers shorter time to first batch, reduced changeover times, increased throughput and production yield. New and existing products are brought to market faster and at lower cost, providing strategic and financial advantage. Production staff can execute library procedures to overcome process upsets. All of which means a more nimble, responsive, and profitable process.

ISA 88: The Shortest Path to Recipe Changes

FlexBatch is designed in accordance with the ISA 88 standard for batch management to help reduce cycle times and life-cycle automation costs. It reduces the need for control engineers by empowering recipe developers and operations staff to make automation changes via intuitive graphical tools. FlexBatch also facilitates compliance with stringent FDA standards such as 21-CFR-Part-11 and the ISPE standard GAMP-5, use of FlexBatch  improves product/record integrity, reduces commissioning time, validation costs, and compliance workloads.

Create Phases and Operations

FlexBatch simplifies the creation, maintenance and documentation of procedures with a graphical editor that creates Procedure Charts for all aspects of production. FlexBatch uses ISA-88 conventions to define transitions between entities which reduces the need for controller programming. The recipe developer creates phase and operation classes and stores them in libraries of reusable objects that recipe developers insert graphically into procedures. Meanwhile, the control engineer can define the plant equipment and the equipment connections within FlexBatch. The actual phases are created using development tools for the D/3 Distributed Control System. This modular approach to creating recipes and phases saves time, reduces testing and errors, and simplifies validation. Because procedures are part of the recipes, producing or modifying a recipe is simple and virtually error free.

Execute and Manage Batches

Operators create, schedule and manage campaigns of assembled recipes to fulfill customer orders or production targets.  Whether running batches on a single production line or at multiple facilities,  operators can visualize and adjust production to meet changing customer demands, assign equipment to specific batches, or modify recipe parameters and procedures associated with individual or multiple batches.

Modify On-the-Fly

At any point during recipe development and execution, personnel can modify Recipe Parameters (ex: Amount of enzyme to add), Recipe Procedures (ex: Don’t use agitator for this batch), Production Schedule (ex: Make 10 batches instead of 5), Batch Start Rules (ex: Start batch after a certain operation completes), Equipment Utilization (ex: Only use Kettle 2 for this batch), or scale Batch Amount (ex: 500kg instead of 200kg)

Document and Analyze

With FlexBatch reporting tools, users can create custom campaign and batch reports to document all activity associated with batch execution.  FlexBatch also includes batch analysis tools to allow operations staff to monitor and analyze production line performance against established KPI’s.

Screen Captures

Create Operations graphically with the Procedure Editor.

Create Operations graphically with the Procedure Editor.

Organize phases and operations in class libraries and assign valid equipment with the Configuration Manager.

Organize phases and operations in class libraries and assign valid equipment with the Configuration Manager.

Assemble Unit Recipes into Master Recipes using the Procedure Editor.

Assemble Unit Recipes into Master Recipes using the Procedure Editor.

Approve recipes and make them available to production.

Approve recipes and make them available to production.

Create campaigns, schedule batches and adjust properties with the Control, Schedule, and Production views.

Create campaigns, schedule batches and adjust properties with the Control, Schedule, and Production views.

 

  • D/3® Keeps it Cool at Major Particle Accelerator

    DESY relies on D/3®, FlexBatch®, and TotalVision® Process HMI for 24/7 operation of refrigeration plant. The German Electron Synchrotron (DESY) – located in Hamburg and Zeuthen – is one of five large accelerator centers in the world at which physicists study the world of elementary particles. Several hundred men and women work together on experiments in international groups, where, over the course of years of collaborative effort, they design, build, and operate complex measuring instruments the size of buildings and evaluate millions of items of data. Four such groups are currently working at DESY at the large underground Hadron Electron Ring Accelerator (HERA).

    August 20, 2014

  • FlexBatch® ISA-88 Batch Software Adds Revenue

    Major Dye Manufacturer Increases Monthly Production by 300,000 Pounds of Product, Adding More Than $23 Million in Annual Revenue. The customer in this scenario is a leading company dedicated to…

    August 1, 2012

  • FlexBatch® ISA-88 Batch Management Overview Brochure

    FlexBatch® integrates recipe management with the manufacturing process by making the automation procedure part of the recipe. Developers, engineers and production staff can quickly develop and modify documented recipes, and immediately schedule them for production.

    September 11, 2012

  • FlexBatch® Recipe & Batch Control Datasheet: A4

    Control of batch manufacturing and product recipes represents a plant’s biggest challenge and greatest opportunity for competitive advantage. After all, efficiency and uniformity impact yield and ultimately R.O.I. Now, you can integrate recipe management and the manufacturing process with FlexBatch®.

    December 21, 2010

  • FlexBatch® ISA-88 Batch Management Software Datasheet

    Control of batch manufacturing and product recipes represents a plant’s biggest challenge and greatest opportunity for competitive advantage. After all, efficiency and uniformity impact yield and ultimately R.O.I. Now, you can integrate recipe management and the manufacturing process with FlexBatch®.

    November 17, 2010

  • FlexBatch® 配方和批控制 Datasheet (Chinese)

    Control of batch manufacturing and product recipes represents a plant’s biggest challenge and greatest opportunity for competitive advantage. After all, efficiency and uniformity impact yield and ultimately R.O.I. Now, you can integrate recipe management and the manufacturing process with FlexBatch®.

    April 1, 2008

  • Additional Datasheets, Application Notes, Customer Success Stories and other documents in our documentation library

  • FlexBatch® Production Operator [#S466]

    AIken, SC Office

    A two-day course covering the use of FlexBatch® to create and execute campaigns and batches. Details of the Production Displays provide students with interactive tools to create, monitor or modify the status of active batches.

    July 27, 2015 – July 28, 2015

  • FlexBatch® D/3® Recipe Developer [#S467]

    Aiken, SC Office

    A three-day course covering the use of FlexBatch® Production Displays to create, execute and monitor campaigns and batches. Students will be able to use the Configuration Management software to create and modify new master recipes.

    July 27, 2015 – July 29, 2015

  • FlexBatch® D/3® Control Engineer [#S468]

    AIken, SC Office

    A five-day course detailing the use of FlexBatch® with a D/3® Distributed Control System. Details on the various Production Displays provide the user with tools to create and monitor campaigns and batches.

    July 27, 2015 – July 31, 2015

  • D/3® SABL® [#S456]

    Aiken Training Office

    A five-day course, using D/3® software, covering the steps involved in developing and using the SABL® package.

    August 17, 2015 – August 21, 2015

  • D/3® User [#S452]

    Aiken Training Office

    A ten-day entry level course using D/3® software explaining the architecture and configuration of the D/3®, operation and control of the D/3® Operator Console, and the configuration of the Continuous Control Database.

    September 14, 2015 – September 25, 2015

  • FlexBatch® D/3® Recipe Developer [#L467]

    Denham Springs, LA Office

    A three-day course covering the use of FlexBatch® Production Displays to create, execute and monitor campaigns and batches. Students will be able to use the Configuration Management software to create and modify new master recipes.

    October 5, 2015 – October 7, 2015

  • FlexBatch® D/3® Control Engineer [#L468]

    Denham Springs Training Office

    A five-day course detailing the use of FlexBatch® with a D/3® Distributed Control System. Details on the various Production Displays provide the user with tools to create and monitor campaigns and batches. New recipes are developed and then validated through batch execution.

    October 5, 2015 – October 9, 2015

  • D/3® SABL® [#M456]

    Owings Mills Training Office

    A five-day course, using D/3® software, covering the steps involved in developing and using the SABL® package. Students will develop the Sequence Database and SABL® programs necessary to manipulate and interact with the continuous database and operator console.

    October 19, 2015 – October 23, 2015

  • D/3® User [#S452]

    Aiken Training Office

    A ten-day entry level course using D/3® software explaining the architecture and configuration of the D/3®, operation and control of the D/3® Operator Console, and the configuration of the Continuous Control Database.

    November 2, 2015 – November 13, 2015

  • D/3® SABL® [#S456]

    Aiken Training Office

    A five-day course, using D/3® software, covering the steps involved in developing and using the SABL® package.

    December 14, 2015 – December 18, 2015

  • D/3® Network Management [#S427]

    Aiken, SC Office

    A two-day course designed especially for the D/3® users. This industrial networking environment course presents modules on industrial hubs, KVM(s), switches, routers, VPN(s) and firewalls with a focus on MTBF (mean time between failure).

    February 18, 2016 – February 19, 2016

  • Windows Security for D/3® [#S435]

    Aiken, SC Office

    A five-day course is “packed” with the latest security information and documentation you need to learn the dangers and defenses you can use to evaluate and support the security of a Microsoft Windows system configured for D/3® operation.

    March 14, 2016 – March 18, 2016

  • This video introduces the D/3, the distributed control system trusted by many Fortune 100 companies to keep their global operations’ continuous and batch processes running smoothly and efficiently. Part one reviews the system architecture and configuration tools.

    July 07, 2015

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