Elipse Software

A batch process is the one where the outcome can only be achieved via finite batches. Among other characteristics, batch processes usually work within a timeframe (that is, they have a start and end time), produce an expected number of products each time, and are based on a well-known sequence of stages called “recipe”. Recipes may vary from product to product, and each may have different amounts and types of input/output, parameters, and steps to be followed.

Some products that are manufactured in batches are:

• Beverages (including beer).
• Pharmaceuticals and vaccines.
• Animal feed.
• Food.
• Cosmetics.
• Hygiene and cleaning products.
• Chemical supplies.
• Enzymes, among others.

ISA S88 standard provides guidelines and recommended practices as appropriate for the design and specification of batch control systems, regardless of their automation level, providing a flexible structure that can quickly adapt to changes in products and in the process itself. Compliance to ISA S88 not only facilitates systems integration, but also ensures that the best practices are followed, thus resulting in greater efficiency and quality.

Simplistic batch solutions that don’t quite follow the standard may seem cheaper, but have many problems embedded in their cost, especially due to their lack of flexibility. To change a product’s recipe amidst a stifled solution, clients may have to recreate from scratch the whole process automation logic, from SCADA/HMI to Controllers/PLCs, which implies higher costs and longer deadlines.

On the other hand, solutions from traditional providers are old-fashioned and expensive. Elipse Factory Batch is a safe, robust alternative that can be easily learned and implemented, with an excellent cost/benefit ratio.

Features 

• Sets or imports registrations of materials, recipes, formulas, procedures, and production orders from an ERP.
• Sets Unit types and their instances.
• Uses IEC 61131’s SFC (Sequential Function Block) language, which provides greater flexibility when setting up production steps (procedures).
• Tracks materials, orders, and detailed history of each item’s productions; these can be visualized via dashboards and customized reports.
• Executes several actions and controls. There are 3 operation/production modes: manual, semiautomatic, and automatic.
• Synchronizes the results to external systems, including ERP.

Benefits 

• Operation Efficiency: Optimized process execution shortens the cycle and increases productivity.
• Consistent Quality: Rigorous control of parameters and recipes ensures high-quality products with little variation, which results in greater compliance.
• Real-time Monitoring: Elipse Factory Batch provides continuous process follow-up, which allows for easily spotting issues and quickly making decisions.
• Cost Cutting: Less waste and fewer mistakes lead to a significant reduction in operational costs in the long run.
• Flexibility and Scalability: Fast adaptation to new demands and easy expansion of operations follow the business’ growth.