What is Batch and Recipe Control?
Advanced automation for consistent, efficient, and traceable batch manufacturing processes.
Batch control is the practice of managing manufacturing processes that produce goods in groups (batches) rather than in a continuous stream. It ensures each batch is executed correctly, consistently, and safely through automated sequences and precise monitoring.
Recipe control deals with managing the set of instructions and parameters that define how to make a particular product. A recipe includes ingredients or raw materials, equipment requirements, and step-by-step procedures for production.
Batch Processing
Manufacturing products in defined quantities rather than continuously
Used extensively in food, beverage, pharmaceutical, and specialty chemical industries
Each batch follows a specific sequence of operations before completion
Allows quality checks and formula adjustments between batches
Recipe Management
Digital formulas that define product specifications and process parameters
Includes ingredients, quantities, equipment settings, and procedures
Enables consistent reproduction of products across different batches
Supports product variations and customisation through recipe changes
Together, batch and recipe control systems ensure that the right recipe is selected for each production run and that all process steps (mixing, heating, cooling, etc.) occur in the correct sequence with the correct settings, delivering consistent quality products every time.
Key Principles of Batch and Recipe Control
Consistency and Quality
Automated systems ensure each batch is made the same way every time, maintaining uniform quality. This consistency is crucial in food production to meet taste and safety standards, and in other industries to meet product specifications
Traceability
Every batch is assigned a unique identity (batch number) and recorded in detail. The system logs critical data including ingredient sources, processing parameters, and operator actions, enabling complete traceability for quality assurance and compliance.
Efficiency
Batch control systems improve efficiency by automating sequences and reducing manual effort. They coordinate equipment to run processes with optimal timing, minimising downtime between batches and reducing human errors.
Flexibility
Using digital recipes makes production processes highly adaptable. Operators can switch between different product recipes or update formulations without reconfiguring physical equipment, enabling quick changeovers and product customisation.
Our Batch Control Solutions
At Sull Systems, we design and implement state-of-the-art batch and recipe control systems that follow industry standards like ISA-88 while addressing your specific manufacturing requirements:
Industry Specific Implementations
Our development team implements robust CIP communication in your control systems
Configuration of implicit I/O connections for real-time data exchange
Development of explicit messaging routines for parameter access
Implementation of producer/consumer data models
Custom function blocks for Siemens PLCs to interface with CIP networks
Our Batch Automation Systems
We deliver comprehensive batch automation solutions that include:
ISA-88 compliant batch management software implementation
PLC programming for equipment phases and unit operations
Operator interfaces with intuitive batch controls and visualisation
Integration with existing equipment and control systems
Batch scheduling and resource management tools
Electronic batch records and reporting systems
Recipe Management Systems
Our recipe management solutions enable efficient creation, storage, and execution of manufacturing recipes:
User-friendly recipe editors for process engineers
Secure recipe storage with version control and audit trails
Recipe approval workflows with electronic signatures
Parameter scaling for different batch sizes
Recipe transfer between development and production environments
Support for master recipes, site recipes, and control recipes
Integration Services
We specialise in integrating batch systems with your broader manufacturing environment:
Connection to ERP systems for production scheduling
Integration with MES for production tracking and reporting
Material management and inventory control interfaces
Historian databases for long-term data storage and analysis
Clean-in-Place (CIP) system integration for automated cleaning cycles
Technology Platforms
We work with all major batch control platforms to deliver the right solution for your specific needs:
Siemens SIMATIC PCS 7
Integrated batch management with SIMATIC Batch, ideal for complex processes requiring tight integration with Siemens hardware. Strong in pharmaceuticals, chemicals, and large food & beverage operations.
AVEVA (Wonderware) InBatch
Hardware-agnostic batch management system that works with various PLCs. Excellent for multi-stream batch management and flexible manufacturing environments that need to adapt quickly.
Rockwell PlantPAx
Modern batch control using FactoryTalk Batch with Allen-Bradley PLCs. Widely used in life sciences and food production with excellent compliance features and scalability from small to large installations.
Emerson DeltaV Batch
Comprehensive DCS-based batch solution with robust recipe management and reporting capabilities. Strong in regulated industries requiring detailed electronic batch records.
As an independent systems integrator, we select the platform that best fits your requirements, existing infrastructure, and long-term strategy. Our expertise spans all major vendors, allowing us to provide objective recommendations.
Benefits of Our Batch Control Solutions
Consistent Product Quality
Our batch systems ensure every batch follows the exact same recipe and process steps, eliminating variations between batches. This consistency builds consumer trust in food products and ensures efficacy in pharmaceuticals.
Improved Efficiency
Automated batch sequencing minimises downtime between batches, optimises resource usage, and reduces human error. Our clients typically see production increases of 15-30% after implementing proper batch control.
Enhanced Flexibility
Digital recipe management allows quick product changeovers and the ability to introduce new products without equipment modifications. Adapt to market demands or customer requirements with minimal disruption.
Complete Traceability
Every batch is documented with detailed electronic records, allowing you to trace any quality issue to its source. This supports regulatory compliance and enables targeted recalls if ever needed.
Regulatory Compliance
Our systems help meet industry standards and regulations such as FDA 21 CFR Part 11, EU GMP Annex 11, and food safety requirements with secure electronic records and appropriate audit trails.
Scalable Production
Easily scale production by increasing batch frequency or running multiple batches in parallel. Our solutions support growth without proportional increases in staff or complexity.
Why Choose Sull Systems?
ISA-88 Expertise: Our engineers are thoroughly trained in ISA-88 standards and best practices for batch control.
Multi-Platform Knowledge: We work with all major batch platforms (Siemens, Rockwell, AVEVA, Emerson) and can recommend the best fit for your needs.
Industry Experience: We understand the specific requirements of food, pharmaceutical, and chemical batch processing.
Full-Service Approach: From initial concept and design through implementation, commissioning, and ongoing support.
Validation Support: We provide documentation and testing protocols for regulated industries requiring validation.
Scalable Solutions: Our systems grow with your business, from single-unit batch control to plant-wide batch management.
Welcome To Sull Systems 