Batch Control

Batch-oriented production with zenon

The Batch Control Module enables zenon to be the perfect
solution for batch-oriented production processes. Based on the
ISA-88 standards, production processes are efciently controlled
and monitored. An intelligent structure and seamless integration
in zenon facilitates quick implementation and efcient validation.
Hardware independency enables freedom, exibility and
provides a cost effective solution. The outstanding usability of
the graphical interface allows for simple and efcient operation.
standard-compliant:
ISA-88 compliant: Batch Control adheres to the strict mo-
dels and procedures to be ISA 88 compliant. Observing the
strict division between the execution of a Batch recipe and
the implementation of equipment control functions as de-
scribed in the standard.
FDA 21 CFR Part 11: Batch Control in zenon offers full FDA
CFR-21 Part 11 compliance, right out of the box.
hardware independent
Batch Control in zenon runs in a PC or server environment,
and is independent of the equipment PLCs in use. Memory
and CPU-intensive applications can therefore run on the PC
hardware and lean PLCs can be used for implementation at
the process level. Strong synchronization with the process
guarantees control in all conditions.
simple handling
Batch Control offers two distinctive graphical interfaces for
operation of the Batch Control Module in the Runtime. Both
are intuitive and very easy to use. The recipe design envi-
ronment is aimed at people without automation experience,
to facilitate process and operation design.
Create recipes
Validate and release recipes
Start recipes
Monitor execution
Read back executed recipes
modern, graphical interface
The operator can see at frst glance the status of a recipe
together with the procedures and phases within. Dynamic
coloring, icons and tooltips provide comprehensive infor-
fast facts
Hardware independent
Fully integrated in zenon
Simple operation
Modern graphical interface
ISA-88 und FDA 21 CFR Part 11 compliant
Network capable
fact sheet #34
mation on the current status and completed control recipes.
Batch Control in zenon offers previously unmatched usabi-
lity in batch production. Two different editors are available
for creating and editing recipes in the Runtime. The Matrix
Editor, is used for simple sequential execution of phases and
operations in recipes; and the PFC Editor, is used for more
complex process recipes.
continuous improvement process
Batch Control in zenon optimally supports the continuous
improvement processes in a batch based processes. Due to
the execution of the Batch Logic on the PC, the equipment
control level can stay untouched while changes are made to
the process operations. This is a crucial advantage, particu-
larly in validated environments. Process experts can easily
optimize available recipes, independent of the machine au-
tomation.
integration in zenon
The Batch Control Module is fully integrated in zenon. All
other modules and features can be used seamlessly in con-
junction with Batch Control. This facilitates quick enginee-
ring and integration in complex HMI/SCADA solutions.
Batch Control in zenon can therefore automatically make
use of the following functionalities:
Existing user administration (including Active Directory
connection / ADAM - LDS)
Integration of CEL and AML (Audit Trail)
Message Control for sending messages
Historian
Vertical integration to ERP systems
Reporting
documentation and reporting
The Batch Control environment is greatly enhanced by the
reporting capabilities in zenon. Impacting and graphical
production reports incorporate Audit-trail, Alarm, and Ar-
chived information.
Comprehensive documentation on Master recipes and Con-
trol recipes is provided, which ensures detailed informati-
on is available for compliance to international regulation
such FDA 21 CFR Part 11; and that quality management is
enforced with information available on prepared and exe-
cuted Control recipes.
Such capabilities open the system to continuous improve-
ment of effciency and quality monitoring.
Batch Control
Batch-oriented production with zenon
Network Batch Control in zenon operates across network distributed systems
Web client capable
Operator control modes Automatic, semi-automatic and manual
Control connections Use any range of PLCs from Siemens, B&R Mitsubishi, Rockwell,
AllenBradley, Beckhoff, ABB, SchneiderElectric and many more
Operate equipment with different PLCs
Flexible integration of other equipment
Scalability With Batch Control in zenon:
Operate several lot based production facilities simultaneously/in parallel
Integrate other equipment parts (e.g. packaging, supply chain)
No restrictions regarding:
Size of recipes
Number of recipes
Number of simultaneously running recipes
Structure of the system, single server for all, include multiple Batch,
Historian, Audit-trail servers
Implementation Flexible implementation in new and existing equipment. According to
ISA-88 separation of recipe execution and equipment operation.
Basic functions
(according to ISA88)
Running
Pausing/Paused
Complete
Stopping/Stopped
Holding/Held
Resume
Restarting
Aborting/Aborted
Graphical Editors in the zenon
Runtime
Matrix editor
Use of all basic functions
Simultaneous sequences
(PFC) Editor
Procedure Function Chart
Use of all basic functions
Simultaneous sequences
Sequence selection
Jumping, Loops
Parallel processes
Decision branches
Unit allocation
Transitions
Test mode Testing of recipes and validation of:
Valid engineering parameters
Correct functional sequence
Manual operation Skip active condition
Escape phase