Modern batch processing relies on flexible ISA-88–based software that streamlines recipe creation, coordinates tasks across multiple units, reduces the need for complex programming, and enables consistent, efficient execution of multistage production processes.
Batch production continues to serve as a foundational operating model in a wide range of industries, including chemical processing, pharmaceutical manufacturing, food and beverage operations, cosmetics, and specialty material production. In these environments, operators increasingly expect batch control software that offers broad adaptability and works seamlessly within the Distributed Control System (DCS) responsible for coordinating and automating plant activities.
Now, with the release of more advanced software for this purpose, the goal of setting up and simplifying recipe development without complex programming is closer at hand.
One of the challenges with batch processing, is the communication and coordination between Units, a task that state-based control can only resolve with significant programming.
According to Mike Davis, Senior Manager, Product Management at Valmet, flexible batch control software was initially conceived to reduce the amount of programming required by recipe developers, in accordance with the ANSI/ISA88 standards first published in 1995 by the International Society of Automation.
“In the past, if you were responsible for creating recipes in a plant, you had to also know how to program the control system,” explains Davis. “With flexible batch software, you don’t need to be able to program a DCS.”
A recipe developer can then group the Phases using a drag-and-drop interface to create an Operation. The order of Operations for a processing unit is defined in the Unit Recipe. All the Unit Recipes required to make the batch from start to finish are grouped in the Master Recipe.
Given the importance of batch processing software for many of its existing customers, Valmet has released Valmet FlexBatch® 8, the latest version of its advanced batch automation and recipe management software. Valmet FlexBatch was originally developed for Valmet D3 automation system and with the newest version, it is fully integrated both with Valmet DNAe and Valmet D3 automation solutions.
FlexBatch 8.0 retains many familiar features that are popular with batch processors, including the ability to draw up procedure charts using a drag-and-drop interface to establish the sequence of Phases and Operations that make up the Unit Recipes, which combined make up the Master Recipe.
The result is a more flexible, efficient, and user-friendly approach to batch processing that frees recipe developers from the burdens of complex programming and supports continuous improvement in both productivity and product quality.
For more information about Valmet’s process automation systems, please visit www.valmet.com.