Batch Control System for Recipe Batch Blending & Automated Batching

Automated batching and material additions (automatic + manual-assisted)

proTrace supports automated and manual-assisted batching to suit process risk, operator oversight requirements and plant constraints. Recipe steps guide the operator, verify additions and record execution for consistent batch outcomes. For plant-wide visibility and supervisory control across multiple lines and assets, explore our SCADA Systems & PLC Control Systems solutions.

Clear & Concise Recipe Control

The proTrace Recipe Management System provides production operatives with easy-to-follow and concise instructions. The recipe formulation created using the proTrace Office Application is displayed on the shop floor operator terminal, which features an animated graphical mimic of the plant. The terminal controls the method of manufacture by processing the recipe formulation commands. It can control mechanical process equipment such as auto-valves, agitators, shear mixers, and more. The system can start, stop, open, close, heat, cool, and control the speed or temperature as required. Automatic and manual material additions are processed by the proTrace Operator Terminal, which can measure them via load cells on vessels or inline flow meters. Real-time material verification and validation can be performed using barcode scanners to ensure correct materials and sequence. The proTrace Recipe System can automatically issue materials into SAP or other ERP systems, recording the actual measured weight to improve material stock usage, reduce operator error, and increase productivity.

Industrialised Shop Floor Operator PC Terminals

Practicon offers industrialized shop floor IP66 Operator PC Terminals specifically designed to operate in harsh production environments. These terminals feature integrated membrane keyboards and touch screens, with options to connect wireless barcode scanners and ID scanners. The ID scanners can read token ID fobs or swipe/RFID ID cards for fast and secure operator identification.

Batch traceability, audit trails and historical batch records

Manufacturing Traceability and Batch Analysis

The proTrace Recipe Batch Blending control system monitors and governs both automatic and manual manufacturing plant processes according to predefined recipe formulations. Each stage of the recipe formulation is recorded as production records, enabling subsequent analysis and batch and material traceability.

Recipe Formulation Design & Historical Data

The proTrace Recipe Management System comprises a central server or suitable desktop PC with a centralised SQL database. This database stores recipe formulations and historical data. Practicon provides the proTrace Office Application, which supports password-protected multi-user network access for viewing historical batch and material data, as well as designing or editing recipe formulations.

Alarm Management & Historical Records

Plant alarms are displayed on the proTrace Operator Terminals and recorded in the historical data records for future analysis. The alarms are time and date stamped, providing valuable information about their occurrence and acceptance. Trending screens are also available on the operator terminal, displaying weight, temperature, pressure, flow rate, and other parameters. The trend data is captured and recorded as historical data against the batch, allowing for further analysis.

PLC/SCADA integration and scalable control architecture

proTrace can be deployed as a stand-alone batch control system or integrated into PLC/SCADA architectures. Integration options support plant visibility, reporting and future expansion.

Flexible Distributed Control System Philosophy

The proTrace Recipe Batch Blending System has a flexible infrastructure that allows for various PLC configurations to suit the customer’s requirements. Practicon offers Siemens or Allen Bradley PLC solutions for plant automation and process control. Additionally, ATEX solutions for hazardous environments, for both gas (Zone 0,1 & 2) and dust (Zone 20,21 & 22, can be provided, ensuring safety in chemical and powder manufacturing companies. Communication standards and protocols such as Ethernet, Profinet, Profibus, Devicenet, and Modbus are used in many applications.

If you require engineered control panels, PLC programming and commissioning for batch plant upgrades, our team also provides Bespoke Control Systems Design and Engineering.

Integration with Enterprise Material Resource Planning Systems

Practicon Recipe systems can operate independently as a manufacturing system or in conjunction with enterprise or material resource planning systems (ERP/MRP) such as SAP, Prism, JD Edwards, and others. This integration allows for seamless coordination and management of manufacturing operations.

Future Proof Design

The proTrace Recipe Management System is modular in design, allowing for future expansion to accommodate additional plant operations or control and integration of more manufacturing vessels.

Typical applications

• Food Batch Blending and Mixing Vessels for liquids/powders
• Chemical Batch Blending and Reactor Vessels
• Controlled Ingredient and Additive Additions
• Recipe-driven Batch Processing with Audit-ready Records
• Shop Floor Operations Linking to ERP/MRP
• Integration with PLC/SCADA and Production Reporting
• Reducing Batch & Material Manufacturing Discrepancy & Errors

FAQs

What is a batch control system?

A batch control system executes and monitors a recipe-defined process to ensure each step happens in the right order, with the right quantities and conditions. It improves consistency, reduces operator error and creates a recorded batch history for traceability and analysis.

What’s the difference between batching systems and automated batching systems?

Batching systems manage the sequence and recording of a batch. An automated batching system also automates key actions such as dispensing, mixing steps, setpoints and verification—helping reduce variability and increase throughput while maintaining control and compliance.

Does proTrace support PLC recipe control?

Yes. proTrace runs recipe instructions to guide and control batch processing and can be deployed with PLC architectures to suit plant requirements, including automatic and manual-assisted stages.

Can proTrace integrate with SCADA and PLC systems?

proTrace can operate as a manufacturing system and integrate within broader plant automation. Typical integrations use industrial protocols and PLC platforms to deliver real-time visibility and controlled execution. Learn more about our SCADA Systems & PLC Control Systems integration approach.

Can proTrace integrate with ERP/MRP systems (e.g., SAP)?

Yes. proTrace can operate stand-alone or alongside ERP/MRP systems to support coordinated manufacturing operations and recorded actuals for production reporting.

How does proTrace help with traceability and compliance?

Each recipe stage can be recorded as production history, including time-stamped events and alarms, supporting batch traceability, investigation, and audit readiness.

Is proTrace suitable for harsh production environments?

Yes. proTrace is designed for industrial use and includes rugged shop-floor operator terminal options intended for challenging environments.

How do I specify the right automated batching system?

Key requirements typically include recipe complexity, number of ingredients, verification needs (e.g., barcode), reporting/traceability requirements, integration needs (PLC/SCADA/ERP), and future expansion plans. Speak to an engineer for a scoped recommendation.