Design and Development of an ISA S88 based Batch Manager System, Supporting the Control of Batch Processes

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Dr. Varjasi István
Department of Automation and Applied Informatics

The purpose of this work is to get knowledge about Batch Controlling Systems, design and develop a Batch Manager application. The aim of these systems is to provide a flexible, easily configurable environment for the users which insures a fast and effective way to change to another product or optimize the current production.

Many kinds of solutions exist in the market for such problems, but most of them is based on a DCS system. A huge handicap of the DCS technology is the price of these complex systems. For smaller production units it’s not worth the investment. In addition these systems are highly configurable, but the development of a special feature is really expensive because of the complexity.

Our aim is to create a Batch Manager application that provides all the benefits of batch controlling with PLC controllers. On the one hand this makes our product affordable, on the other special requirements can be satisfied easily.

Using our Batch Manager, technologists can build their own recipes from the given set of operations and then execute it to get the desired product. At the end of the execution, the application is able to generate a detailed report of the production.

During the design and development we’ve strictly followed the ANSI/ISA-S88.01 standard for batch controlling and its Hungarian equivalent MSZ-EN-61512. Moreover we had to conform to 21 CFR Part 11 and GAMP 5 regulations with our user and electric record handling methods.

After a two year long development I’m proud to say that CS-BATCH Batch Manager application has been installed to two different production units already.


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