Batch Processing for F&B

Applying Batch process engineering using Wonderware solutions

Presented by: Amit Sawant, Pravin Shinde

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 Amit Sawant Pravin Shinde
Webex Session Schneider Electric Schneider Electric

F&B StruxureLab F&B StruxureLab

Department Department

>Topic: Introduction to batch processing

Speaker: Amit Sawant

>Topic: Batch Process Engineering using WW Inbatch

Speaker: Pravin Shinde

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Webex Batch processing for 1 Introduction to Batch Processing

F&B using Wonderware Inbatch 2 Wonderware Inbatch Offer

3 Inbatch Environment overview

4 Learning & Demonstration

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Introduction - Amitkumar A Sawant

With Schneider Electric since 5 years.

Overall 15+ years of experience in process automation in F&B and Life

science.

Managing Global F&B Solutions Lab (Struxurelab) in R&D Centre

Bangalore.

Worked on different automation platforms like Schneider Electric,

Rockwell, Honeywell, Wonderware, GE

Implemented projects worldwide with popular brands like - Nestle, Arla

Foods, General Mills, Danone, Coca Cola, Pepsico, AB In-Bev, Alcon,
Wyeth etc

Worked with technology providers like - TetraPak, GEA, SPX, Ineos,

NNE etc

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Introduction to Batch processing
ISA S88 Batch Standards Way.

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What is Batch production process ?
Finite inputs Ingredient 1, Sequence of processing Finite Output
ingredient 2. activity Step1, Step2,. Finished product

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Batch Process Complexity

Single Product Single Path

Simple

Multi Product Single Path

Medium Complex

Multi Product Multi Path

Complex Needs flexibility

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Traditional Batch Operation

Enterprise Operations

Vendor A Planning and

Home made Excel Reports
Scheduling applications

Paper Copies of SOPs Third party Historians

Improvised Modifications

Local Control System

Multi Vendor & Variant technologies

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Traditional Batch Operation...

No Prescribed form of batch operation.

Missing common terminologies.

Difficult establish requirements .

Complex operational environment not integrated together,

Difficult integrating different vendor offerings

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Why Batch Management ?

Reconcile flexibility and simplicity

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Need of the day

Enterprise wide multi product portfolio.

Simplicity in operation, Flexible to change.

Swift transformation - Localizing raw materials.

Varied equipment configurations.

Multi vendor control system platforms

Agile lab-to-market strategy.

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ISA Standards and global
Impact
Several original ISA standards
are basis of major international
electro technical commission
(IEC) standards.
IEC 61512 : Batch Control
(ISA S88)

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Introducing ISA S88.0x
General guidelines developed specifically for batch industries :
Food and Beverages, Specialty chemicals, Pharmaceuticals, .

Model and methodology for designing and operating control systems for
flexible manufacturing.
Independent of underlying control system (PLC, DCS or IPC)

Independent of basic control algorithms.

Enable with ease verified and validated recipe and automation

Changes.

Provision to handle abnormal conditions / situations

Defining programming standards for batch control

Widely adopted configuration standards for manufacturing.

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ISA S88.0x Philosophy

Separation of the mind and the body

Minimum set of information that uniquely defines the Manufacturing plant

manufacturing requirements of product.
Equipment
Provide production information, formula, procedure,
equipment requirements. Control system

..

Independent Recipe development

Multiple Products Same equipment
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Physical Model

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Physical Model

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Units, Equipment, Modules and Control Modules..

Control module

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Physical Model

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Physical Model

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Physical Model

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Recipe Model

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Recipe Types

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Procedural Model

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Procedural Model

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Procedural Model

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Procedural Model

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Procedural Model

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Connecting Procedural and Physical models

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Wonderware Inbatch
SE Batch management Solution

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What is Schneider Batch?

InBatch is control system independent Batch Management

Software, Designed to effective Model and Automate Batch
Processes
Successfully used, globally since nearly two decades:

1000+ installations globally

Verticals: Pharmaceutical, Life Science, Healthcare, Chemical,

Petrochemical,
Food &Beverage, Construction materials etc.

Long term domain expertise in Ecosystem and Employees

Used with all major PLC brands.

Area of continuous Investment and Industry Standard Support

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Inbatch Strengths

InBatch software excels at automating the most complex batch

processes or when demanding high flexibility in recipe creation and
modification
Empowers Process engineers to rapidly implement recipe changes or
new product recipes

Maximizes production throughput through its multi stream, multi product

batch execution and automation capabilities

Reduces compliance cost with a comprehensive electronic batch record,

material genealogy, security system event trail and large set of reports.

Manage Materials storage, tracing the usage of ingredients during

different batch campaigns and on a smaller scale manage inventory.

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Inbatch Features
InBatch is Flexible Batch Management Software Designed to Model
and Automate Batch Processes
Empowers Process engineers to rapidly implement recipe changes or
new product recipes

Model-based - Easy recipe creation - Consistent with ISA-88

Beyond ISA-88 - Connection & Transfer Management

Recipe import/export/version history using

Comprehensive production history

Electronic Batch Record and Material genealogy, Web based reports

Scalable System Architecture single node to large systems, integration to

ArchestrA System Platform,Foxboro Evo system.

Efficient Batch supervision and governance including standard operating

procedures for manual ops.

Security options and FDA CFR21 Part11 compliance

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Inbatch -Generic Architecture, totally scalable

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Inbatch - Integrated with Wonderware system platform

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Inbatch - StruxureLab Architecture (TVDA)
Architecture I Architecture II

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Batch Integration with process controller - Phase Logic Interface(PLI)
Process Phases at Batch end Process Phases at Process Controller

Synchronize - Exchange commands , states etc..

Phases at batch end should
exchange right commands,
states and parameters to
phases at process controller
end to execute the phase.

The Operational states of phases at Batch end should match with that of
phases at Process controller end
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Inbatch Interface with Schneider PLC - Phase logic Interface(PLI)
Derived Function block (DFB) - PLI Supervisory Functions - WSP

New SEQCTL2 function block compatible to Inbatch phase state engine,

derived from GPL Library SEQCTL1 Unity and WSP components Smart Symbol, Faceplate.

Inbuilt Phase logic interface Module (PLI) which can interface with Part of TVDA Deliverable.
Inbatch Phases for Commands, Status and parameters.
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StruxureLab TVDA - Use case scenario (Physical model)
Yogurt Processing plant

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StruxureLab TVDA - Use case scenario (Recipe)

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Wonderware Inbatch - Environment
Exploring Inbatch Software Learning and Demo

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Introduction - Pravin Shinde

With Schneider Electric since 4 years.

Overall 10 years of experience in process automation in F&B and WWW.

Technical Lead in Solutions Lab (Struxurelab) in R&D Centre Bangalore.

Work experience in F&B, Distillation and Sugar, WWW, Automotive and

Process Automation Projects Level 0 to Level 3.

Worked with renowned end users and consultants - APV,Nestle,Praj, Mahindra,

WETICO etc.

Automation Platforms Allen Bradley, Rockwell, Schneider, Wonderware.

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 Inbatch Environment Configuration and operations

Environment display InBatch features

Process modeling Recipe Comparison
TagLinker Import Export Utility
TrainEdit
MtlEdit
RecipeEdit (Master and Control Recipe)
SecEdit
LogEdit
BatchSched
BatchDspl
BatchReports
PhaseLogic

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TVDA Deliverables and Contact Details

Benjamin Jude

[email protected]

Amit Sawant

[email protected]

Pravin Shinde

[email protected]
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Questions?

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 THANK YOU.

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