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 solutions. Our engineers are experts at the ISA-88 standard 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 standards for batch control system design and integration with MES/ERP systems.

Cybertrol Engineering's BatchWorks enhances recipe management and scheduling functions.

Modules include:  

• Recipe Editor – Allows recipes to be edited and stored.  Allows recipes to be released for production.  
• Recipe Version Control – Keeps versions of all recipes.  
• Batch Scheduler/Campaign Manager – Schedules production across processing units. Once the batch or campaign is scheduled, it is pushed to the controller, which will then display the current batch list on the HMI. The operator selects the desired batch to run and starts it. The system will run the batch per the downloaded batch recipe.  
• Batch Records – Executed batches will store batch records into a database. 
• Batch Report – Batch reports will be created to view the data.   
• Material Management – Inventory consumption data transactions with the ERP after performing batch certification.

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 ANSI/ISA-88-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. 

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.