Recipe and Batch Management

Process agility on steroids

Enforce repeatable quality and increase efficiencies

Industries such as food, chemicals and pharmaceuticals, which create products in batches, require a special kind of operations management.

Like all process operations, they need to enforce repeatable quality and increase efficiencies, but must optimize each batch as a separate process – sometimes switching products; sometimes with stringent clean in place procedures between batches – and sometimes executing many batches in a single day.

Recipe and batch management software helps to manage batch execution more efficiently, allocating equipment, downloading parameters and automating recipe procedures. It also coordinates everything with the plant control systems, interfaces with the operators and directs batch activity, material flow and production records to a historical database.  Batch events trigger electronic workflows for quality sign off procedures or corrective actions in case of alarms or nonconformance. Recipe and Batch management software abstracts recipes from underlying control systems which helps to standardize new product introduction processes and procedures enterprise-wide.

Delivering Recipe and Batch Management

Two Wonderware solutions make up the Wonderware Recipe and Batch management offering:

  • Wonderware Recipe Manager Plus, which is control system independent recipe management software that simplifies management of product formulations, downloading of formula parameter values and recipe execution to produce a specific product on automated equipment.
  • Wonderware® InBatch®, which is control system independent batch management software that can be used for the largest multi-product and multi-stream batch operations, including recipe management, material management, concurrent batch scheduling and execution, server redundancy and electronic batch records management (EBR).

Who needs Recipe and Batch Management?

 

    • Process Engineering and Operations

      1. Product specification (recipe) management – Process engineers need tools to be able to describe the product formula and procedure they developed, so that these recipes can be taken to the shop floor and adopted to produce products according to the specified quality.
      2. Recipe optimization – the faster you are able to produce and reproduce a new recipe right on your production line, the better your business performance will be. Capturing your golden batch setup and tuning your recipes to reproduce the optimal setup is key to maximizing plant performance.
      3. Repeatable quality – each batch or product run requires securing all parameters to follow the specified procedure and setting up production equipment to achieve the quality specification. At the same time machine, material and people conditions are constantly changing conditions.
      4. Regulatory compliance – compliance with today’s regulations requires documentation of all execution events, material flows and quality data. Automated electronic record keeping helps reduce your cost of compliance.

    • Management

      1. Increase operational efficiencies – ensure your people are following the same procedures and adopting best practices. Eliminate quality variations that will impact bottom line results. Capture unique process knowledge from you aging workforce and turn it into standard processes.
      2. Regulatory compliance – reduce the risk of recalls and protect your brand equity by enforcing products produced to specification, govern the recipe management and execution process with detailed traceability and electronic batch records, learn how to avoid extensive manual work for data collection, transformation and quality certificates.
      3. Agility to respond to change in demand – improve time to market to capture market share with new products. Manage more complex products and more product variations without risk to product quality. Take advantage of smaller, but more profitable markets.
      4. Enterprise integration and collaboration – achieve supply chain visibility and decision making support to make better planning decisions. Improve operational performance to improve business performance.

    Optimize Your Business
    with Wonderware MOM

    Use the links below to learn more about how you can bring your batch and recipe management operations to a new level of agility.