Batch Control refers to the automated execution of batch-oriented processes: raw materials are processed according to recipes in defined steps until a batch is complete.
Typical application fields:
Batch Control fundamentally answers three questions:
The international standard ISA-88 (IEC 61512) provides the reference model for batch control:
Essential principles:
Practically, this means: The same master recipe can run on multiple plants with slightly different configurations without reprogramming the complete logic every time.
A batch recipe defines:
Typically distinguished between:
The procedural model controls execution:
This determines when which actions occur in which sequence—independent of which specific unit ultimately executes them.
The physical model ensures recipes aren't "welded" to a single plant:
Batch Control uses this structure to map phases to equipment and control modules. This makes processes change-friendly and scalable.
A batch control system (often part of a process control system or MES) handles:
Recipe Management: Versioning, approval workflows, audit trail, change management
Batch Scheduling & Dispatching: Planning and starting batches on available units, considering cleaning/CIP/SIP
Online Control & Monitoring: Visualization of running batches (step, status, setpoint/actual values, alarms)
Batch Record & Historization: Complete capture of parameters, operator interventions, deviations—foundation for QA, QP review, audits
Reporting & Analysis: Batch comparison, root cause analysis, OEE and throughput analysis at batch level
Professionally implemented batch control delivers:
Quality & Compliance: Reproducible sequences, documented parameter histories, traceability—essential for regulated industries
Flexibility: Adjustment of batch sizes, variants, recipe versions without re-engineering the entire control system
Efficiency: Better plant throughput, fewer operator errors, optimized cleaning and changeover strategies
Standardization: Same recipes and processes across multiple sites, comparable KPIs across plants
Batch Control is classically anchored in the process control system (DCS), but the connection to MES is becoming increasingly important:
In modern architectures, Cloud MES or MOM solutions increasingly handle functions like:
Batch: Clearly defined batches, defined start/end points, strong recipe orientation
Continuous: Continuous material flow, focus on stability and control quality over long periods
Discrete: Piece production (parts/units), often with MES logic like workflows, OEE, sequence planning
Many plants run hybrid scenarios (e.g., batch mixers + discrete filling/packaging lines). A unified model and data approach (ISA-88/ISA-95, MES integration) then becomes a decisive architectural advantage.
Is Batch Control only relevant for pharma and chemicals? No. Wherever production occurs in defined batches (food, cosmetics, coatings, specialty chemicals), batch control principles make sense—often even without full regulatory complexity.
Do I absolutely need ISA-88 to use Batch Control? Formally no. In practice, an ISA-88-compliant approach saves massive effort because recipes, equipment models, and control modules become reusable and manufacturer-independent.
How does Batch Control fit into a Digital Factory strategy? Batch Control provides granular process and quality data for PAT, OEE, digital twins, and comprehensive analytics. Through MES and data platforms, this data becomes usable for digital factory use cases—from predictive quality to global batch benchmarking.