Recipe and Batch Management

Enabling recipe agility with predictable product and process quality

Enforcing Repeatable Quality While Increasing Manufacturing Flexibility and Asset Utilisation

Industries that create products in batches or lots – such as food and beverages, CPG, chemicals, and pharmaceuticals – require a special kind of operations management.

Like all process operations, they need to enforce and ensure repeatable quality and increase efficiencies, but must optimise each batch or production run as a separate process — sometimes switching products; sometimes with stringent clean in place procedures between batches; and sometimes executing many batches in a single day.

Recipe and Batch Management software abstracts recipes from underlying control systems which makes it easy to change and add recipes, and to effectively manage more products or many product variations. It helps manage production execution more efficiently, allocating equipment, downloading formula parameters, and automating recipe procedures. It also coordinates recipe execution with the plant control systems, interfaces with the operators, and directs batch activity and production records to a historical database. Execution events can be used to trigger electronic workflows for quality sign-off procedures or corrective actions in case of alarms or nonconformance.

Recipe Management standardisation across the business helps to streamline the new product introduction processes and to reduce the time to market for new products and product innovations.

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Delivering Recipe and Batch Management

  • Recipe Management is control-system-independent recipe management software that simplifies how you manage multiple product formulas, download formula parameter values, and execute recipe. You would use this to produce a specific product on automated equipment, and to provide a full recipe change and execution history record.
  • Batch Management is control-system-independent batch management software that you can use for the largest multi-product and multi-stream batch operations. This includes recipe management, material management and traceability, concurrent batch scheduling and execution, server redundancy, and electronic batch record (EBR) management.

Who Needs Recipe and Batch Management?

Process Engineering and Operations

  1. Product specification (recipe) management – Process engineers need tools to be able to describe the product formula and procedure they developed, so that these recipes can be taken to the shop floor and adopted to produce products according to the specified quality.
  2. Recipe optimisation – The faster you are able to produce and reproduce a new recipe right on your production line, the better your business performance will be. Capturing your golden batch setup and tuning your recipes to reproduce the optimal setup is key to maximising plant performance.
  3. Repeatable quality – Each batch or product run requires securing all parameters to follow the specified procedure and setting up production equipment to achieve the quality specification.
  4. Regulatory compliance – Compliance with today’s regulations requires documentation of all execution events, material flows, and quality data.

Management

  1. Increase operational efficiencies – Ensure your people are following the same procedures and adopting best practices. Eliminate quality variations that will impact bottom line results. Capture unique process knowledge from your ageing workforce and turn it into standard processes.
  2. Regulatory compliance – Reduce the risk of recalls and protect your brand equity by enforcing products produced to specification, govern the recipe management and execution process with detailed traceability and electronic batch records, and learn how to avoid extensive manual work for data collection, transformation, and quality certificates.
  3. Agility to respond to change in demand – Improve time to market to capture market share with new products.  Manage more complex products and more product variations without risk to product quality. Take advantage of smaller, but more profitable markets.
  4. Enterprise integration and collaboration Achieve supply chain visibility and decision-making support to make better planning decisions. Improve operational performance to improve business performance.

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