For many operators, batch process controls are a black box—it’s unclear what’s inside them, how they’re programmed, or how exactly they control the rest of the system. This presents problems for both operators and engineers. Making even a small change or upgrade requires a service call, or someone on staff with programming knowledge. To service multiple systems or brands using custom languages, engineers need a library of programming knowledge on top of mechanical expertise. Many operators and engineers wonder why batch process controls can’t be accessible, as well as functional and durable. Is it possible to control and change the system with the functionality and integrity of a PLC, without an extra layer of complexity?
Batch Process Control Simplified
No Programming Required
It’s a common scenario: you want to update your process, change a recipe, or replace a machine to improve your product or process. Your field service tech or your own engineers are buried in ladder logic or proprietary programming. Making one process improvement shouldn’t take this long or cost this much.
Instead of learning your machine’s language, the computer should learn your language. The Batch Box integrated batch controller does it. BatchBox allows technicians or operators to install, program and reprogram the entire batch mixing, weighing and measuring process with word-based commands. A simple interview process removes the layer of complexity that makes batch process control programming so inaccessible. The BatchBox controller asks you about your system in plain English, then takes care of the programming for you.
Program or reprogram your automated process system with no programming required.
Complete System Control
Process visibility is a common problem for many manufacturers. Scale instruments control dosing and measurement, but can’t control metered liquids or mixing. PLCs can coordinate more parts of the system, but can’t communicate the results with operators. When it comes to comprehensive batch process management, there’s always a roadblock.
Upstream and downstream process visibility and control is essential. If one process isn’t correct, every subsequent process will also be off. The BatchBox solves this problem with complete system control built in. Mixers, metered liquids, feeders, scales, motors, alarms and every other part of the process are all connected and controlled from one secure, but accessible device.
Gather System Data
Simply controlling and coordinating ingredients and mixing is no longer enough. Optimizing your product and your process requires data: volume, time, maintenance, accuracy, quality and defects. However, an archive and database aren’t built in to the brains of most systems, leaving operators without any knowledge of their batch process system day-to-day.
The BatchBox is programmed to gather and archive batch process control data. From production volume to no-flow conditions, maintenance time, measuring accuracy, product defects and more, you have a full record of what your system is doing. If something goes wrong, you know what, when, and why. In the long-term, you have the tools to uncover problems and optimize your system.
Change Your Recipe At Any Time
Some recipes are tried and true, and stay the same for years at a time. But most of the time recipes change slightly; flavorings, vitamin mixes, colorants, and dozens of other changes. In order to accommodate all the ingredients and recipes that are required, you need a database, but traditional PLC’s do not have enough memory storage to accomplish this. Using an industrial computer in conjunction with a PLC rack of I/O gives you the best of both worlds. A system that is hardened for rough industrial environments, and a PC that is capable of storing all of the recipe and ingredient information.
When upgrading your system controls, replacing a faulty board or making other periodic fixes, operators, technicians and engineers encounter a common problem; the parts or information they need is only in one place. This means accepting one price, one timeline and one configuration, no questions asked.
All control systems inevitably require some maintenance or repairs, but you do have options about how to make those repairs. The BatchBox is built with all off-the-shelf components, so you can make repairs or replacements at any time. This also gives you more freedom to shop around or select a dealer with the fastest lead times.
Previously, PLCs and scale instruments have been black boxes, with only a few experts knowing what is in them or how they work. However, batch process controls do not have to be a mystery or a point of frustration. BatchBox is value-added technology giving end users simplicity and functionality, and giving distributors a competitive value proposition.
BatchBox is designed to work with the most popular existing equipment and scale instruments, including Mettler-Toledo, Cardinal, Hardy, Rice Lake, and many more. Designed with both end-users and distributors in mind, BatchBox allows anyone to become an expert on their batch process systems, with no extra training or tools required. Take a look at the spec sheet to learn more about BatchBox for your system or your customers today.