Batch Production
Control-Service – Batch Production
These solutions also support additional stages of the technological process, such as heating, cooling, mixing, and batch aging.
Batch systems significantly improve operational efficiency within a facility. Production can be carried out simultaneously across multiple installations. The system automatically reserves equipment, establishes dosing routes, manages process interlocks, controls the availability of tanks and mixers, and monitors inventory levels of raw materials and finished products, ensuring smooth execution of planned production.
Batch production systems are used in a wide range of industries, particularly in the chemical, petrochemical, food and beverage, pharmaceutical, and building materials sectors.
The solutions we design ensure process repeatability, high product quality, and full control over recipe execution.
Control system integration for batch production
We design and implement control systems for batch production that enable precise planning and execution of processes in accordance with predefined recipes. Batch systems allow accurate dosing of ingredients into mixers, reactors, and tanks in a specified sequence and proportion, whether by weight, volume, or molar ratio.These solutions also support additional stages of the technological process, such as heating, cooling, mixing, and batch aging.
Batch systems significantly improve operational efficiency within a facility. Production can be carried out simultaneously across multiple installations. The system automatically reserves equipment, establishes dosing routes, manages process interlocks, controls the availability of tanks and mixers, and monitors inventory levels of raw materials and finished products, ensuring smooth execution of planned production.
Batch production systems are used in a wide range of industries, particularly in the chemical, petrochemical, food and beverage, pharmaceutical, and building materials sectors.
The solutions we design ensure process repeatability, high product quality, and full control over recipe execution.
CS PASS System
We offer our proprietary Control-Service Process Automation & Supervisory System (CS PASS), designed for advanced batch production installations. The system provides a high level of flexibility and scalability, making it suitable for both large-scale and smaller control systems.
Business value
The system supports increased production efficiency by shortening cycle times, improving resource utilization, and enhancing OEE metrics, which directly translates into higher productivity and improved plant profitability.Key benefits:
The system enables dynamic management of raw materials and equipment, allowing smooth planning and execution of subsequent production batches without unnecessary downtime.
Process safety
We implement process and safety interlocks that protect the installation, technological process, and personnel.
Electronic Batch Record (EBR)
The system automatically records data for each production batch, including process flow, technological parameters, and operator actions, eliminating paper documentation and ensuring full production traceability.
Fast implementation
The use of proprietary application development tools shortens system design and commissioning time and reduces the risk of errors.
Intuitive recipe management
The graphical interface allows easy creation and modification of recipes without programming, enabling faster deployment of new products.
Precise process control
The operator has continuous access to information about system status, alarms, and process progress, enabling quick decision-making and full production control.
System reliability
The use of redundancy and virtualization ensures high system availability and continuous operation of the installation.Process simulation
The CS PASS system includes an integrated simulator that enables testing of the control system and operator training without interfering with the real process.The simulation replicates plant operation and allows safe verification of all system functions before commissioning.
Batch production systems (InBatch, Wonderware System Platform) delivered by our engineers in recent years:
2021 Control system for a resin condensation plant – production of decorative laminates
2020 System for production of emulsion paints and fillers
2018 Construction of a water-based paint production line with InBatch system
2017 Raw material dosing system for bulk solids – Pustków
2016 Chemical reactor control system – Reactor 2
2015 Chemical reactor control system – Reactor 1
2014 Expansion of paint production control system
2013 Paint production control system (chlorinated rubber coatings)