Batch Control & Recipe Management Systems | ISA-88 & ISA-95 Standards

Cybertrol leverages extensive experience in delivering advanced batch control solutions for complex processes. Our engineers specialize in ISA-88 standards, integrating batch control with MES/ERP systems to enhance production scheduling, recipe management, and lot tracking. With a focus on compliance, we ensure solutions meet FDA 21 CFR Part 11 regulations for electronic records and signatures, providing both flexibility and precision in every project.

Cybertrol Engineering is a recognized leader in Batch Control and Recipe Management System Integration

Cybertrol's experience is the result of numerous, successful batch control system projects for a variety of challenging batch applications. Our engineers are experts at ISA-88 standards for batch control and modeling the enterprise for optimal batch processing. We define batch control and recipe execution solutions for manufacturing operations by analyzing the physical system and the procedural requirements. Cybertrol Engineering will help you understand how batch control systems can facilitate scheduling production, recipe editing, formulations, system validation, lot tracking, flexible requirements, and more.

Our batch control system designs take into consideration FDA 21 CFR Part 11 (Code of Federal Regulations for electronic records and electronic signatures). From system functional requirements specifications to software module construction, Cybertrol’s designs comply with the International Society of Automation standards including ISA-88 and ISA-95 for batch control system design and integration with MES and ERP systems.

PLC and server-based batching solutions

ERP integration for inventory accuracy

Recipe management, storage, and version control

Production scheduling

Batch history logging and recording

Full data collection and reporting

Flexibility to add functionality

Materials traceability

BatchWorks MES software for extensibility

Utilities optimization

Batch Reports

Detailed Batch Report: This report will show batch start and end times, batch ID, recipe used, and setpoint versus actual for ingredient additions, as well as any other alarms or events that occur during the batch operation.

Completed Batches by Date Report: This report shows all batches that were completed between two user-specified dates. Each batch is shown as a link that navigates to the summary batch report for the selected batch.

Summary Batch Report: The summary batch report can be run for any production batch and shows recipe, run time, and both individual and aggregate (total) ingredient usage by material type.

Golden Batch: Golden batch reports allow for the definition of what an ideal batch should “look like”, then allows for future executions to be compared via the standard using an overlaid trend. A batch is defined as anything with a defined “beginning and end” and could be a batch of product, a CIP wash, or a 24-hour trend of water consumption or effluent discharge.

BatchWorks® – Batch Management and Integration Software

BatchWorks is Cybertrol Engineering’s web‑based batch management and integration platform, designed to connect batch execution systems with higher‑level business systems such as MES and ERP. It provides real‑time visibility into production performance, material consumption, inventory availability, batch cycle time, and batch quality.

BatchWorks is built using ISA‑88 (S88) batch control principles, with phase‑based recipes that align operational execution with manufacturing and business requirements. Supervisors and operators can create, copy, and manage recipes, schedule and run batches, monitor batch progress, and generate comprehensive batch reports—all from a centralized, browser‑based interface.

Web‑based platform for enterprise‑level batch management

Centralized recipe management across one or more batching systems

Production scheduling and campaign management

Real time batch reporting and historical batch records

Integration with MES, ERP, and other business systems

Compatible with PLC based or server based batch execution engines

BatchWorks Software from Cybertrol Engineering

Enhance Your Batch Process

BatchWorks Integration Software

Includes a web-based user interface for easy formulation management, recipe consolidation, and production scheduling.

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Batch Lite – PLC Based Batch Execution

Batch Lite is Cybertrol Engineering’s PLC‑based batching engine, designed for executing batch logic and recipes directly in the controller. It delivers flexible, reliable batch control without the complexity or infrastructure required for a full server‑based batch system.

Batch Lite uses S88‑based programming concepts to structure batch sequences into phases and steps, enabling consistent, repeatable operation. Recipes are most commonly stored and executed in the PLC, providing a streamlined architecture that is well suited for many process applications.

PLC resident batch execution engine

Recipe storage and execution directly in the controller

Phase based batch sequencing using S88 concepts

Supports fully automatic and semi automatic batch operation

Lower system complexity and cost compared to server based batch systems

Can be paired with FactoryTalk View or other HMIs for operator interaction

Can be structured to support future expansion or migration if system needs grow

What’s the Difference?

In simple terms:

Batch Lite executes the batch
BatchWorks manages, integrates, and reports on batches

Batch Lite focuses on real time batch execution at the control level, while BatchWorks operates at a higher system level, coordinating recipes, schedules, reporting, and integration across systems and facilities.

When to Use Batch Lite Versus BatchWorks

Use Batch Lite when:

A PLC centric batching solution is preferred

Batch processes are linear or moderately complex

Shared equipment and advanced orchestration are limited

Lower system cost and architectural simplicity are key drivers

Batch execution does not require direct MES or ERP integration

Use BatchWorks when:

Centralized batch management is required across one or more systems

Integration with MES, ERP, or other business systems is needed

Production scheduling, campaign management, and reporting are important

Enterprise visibility into materials, inventory, and batch performance is required

Batch execution systems (PLC based or server based) need to be coordinated

Use Batch Lite + BatchWorks together when:

Batch execution occurs at the PLC level

Enterprise level scheduling, reporting, and integration are also required

A scalable solution is needed that can grow with future operational or business needs

Cybertrol's FactoryTalk Batch Experience

As a Rockwell Automation PartnerNetwork Gold System Integrator, Cybertrol is fully competent with FactoryTalk Batch, a Rockwell Automation software that allows end users to apply one control and information system across their entire process to improve capacity and product quality, save energy and raw materials, and reduce process variations and human intervention.

Using ISA88-based functionality, recipes and processes can be developed independently of process equipment. Users can easily change recipe parameters, add new batches, or define which equipment your batches use; without requiring engineering or automation system changes or revalidation.

Cybertrol has developed tools to leverage the power of FactoryTalk Batch software along with additional innovations to allow for corporate recipes from the ERP to be pushed into the system, with detailed reporting solutions as a result.

With FactoryTalk Batch, end users can:

Create and manage recipes and execute them automatically

Reduce hours that are needed for validating and commissioning

Configure physical and procedural models

Collect electronic batch data to generate reports for compliance or process improvement

Simulate the entire batch process

Case Studies

Case-Study-Pharmaceutical-Processing-with-PlantPAx-and-FactoryTalk-Batch

Smarter Pharmaceutical Processing with PlantPAx & FactoryTalk Batch

Cybertrol partnered with a leading biotech manufacturer to modernize and expand their Research and Development Center in Wisconsin, implementing advanced process control and batch automation systems that enabled continuous production during renovation and positioned the facility for expanded manufacturing capabilities.

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Pharma-Manufacturer-Enhances-Productivity-FactoryTalk-BatchWorks

Pharma Contract Manufacturer Enhances Operations with FactoryTalk

A pharmaceutical contract manufacturer needed to modernize its operations, improve data visibility, and prepare for 21 CFR Part 11 compliance. Cybertrol Engineering delivered a secure, centralized control system using the FactoryTalk suite and BatchWorks, laying the foundation for scalable growth and streamlined reporting.

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PlantPAx and FactoryTalk Batch Streamline Operations for Interplastic

Interplastic Corporation, a leader in specialty resin production, sought to modernize the batch processing system at its Fort Wright, Kentucky, facility. The goal was to enhance product quality and consistency through total automation while addressing inefficiencies and streamlining operational challenges.

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Greenfield Install at World's Largest Ice Cream Manufacturing Facility

A major global food manufacturer needed greenfield installation to create the largest ice cream manufacturing facility in the world. Cybertrol led the project to create a new robust facility capable of running 24/7 with zero downtime.

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