Flexible and Advanced Software Solutions for Batch Processing Success

[Cengiz Özemli]

## The Role of Flexible ISA-88 Based Software in Batch Processing Success

Today's batch processes facilitate recipe creation with flexible ISA-88 standard-based software, coordinate tasks across multiple units, and ensure the efficient execution of multi-stage production processes.

The batch production model continues to be the fundamental mode of operation in many sectors, such as chemical, pharmaceutical, food and beverage, cosmetics, and specialty material manufacturing. In these fields, operators demand control software that offers broader compliance and full integration with DCS (Distributed Control System).

Thanks to new-generation software, the goal of setting up and simplifying recipe development without complex programming has become more achievable.

### Batch Processing and Core Operations

In batch processing, products are manufactured through a series of repeatable and recipe-based operations. Materials are added in specific quantities, parameters such as temperature, mixing speed, pressure, and timing are controlled, and the product passes through stages in a fixed sequence until completion.

After each batch, equipment can be cleaned, adjusted, or reconfigured, making it ideal for products requiring formula changes, consistency, or precise manufacturing. Even continuous processes can utilize batch operations for purification, mixing, or finishing steps.

### Coordination Between Units and the Role of Software

One of the challenges of batch processing is communication and coordination between units. State-based control can only achieve this with detailed programming.

Batch processes typically consist of units; material is processed in one unit and transferred to others. Units produce the product through operations such as heating, cooling, material addition, mixing, or separation.

Batch processing software collects unit tasks and automatically runs pre-planned batches without user intervention. It coordinates data flow, program execution, and error management, ensuring that repetitive complex operations are reliable and efficient.

### Valmet FlexBatch 8 Software

Valmet aimed to develop flexible batch control software in accordance with ANSI/ISA-88 standards, reducing the need for complex programming. This software offers easy modification of parameters, procedures, and production plans.

Valmet FlexBatch 8 provides advanced batch automation and recipe management, offering operators a user-friendly platform that requires no programming. Working in full integration with Valmet DNAe, the software facilitates the control of batch operations with a web-based user interface.

As stated by Tiina Stenvik, this new version is a significant development for fast, safe, and traceable production in the chemical industry.

### Valmet FlexBatch Features

• ISA-88 compliant advanced batch automation
• Creation of procedure graphics with a drag-and-drop interface
• Easy modification of recipe parameters and operation sequences
• Visualization of batch operations by monitoring live procedure graphics
• Manual step approval and advanced user permissions
• Rapid reuse of recipe components
• Increasing production efficiency with campaign tools
• Electronic record keeping and compliance with FDA 21 CFR Part 11 and ISPE GAMP-5
• Full integration with Valmet DNAe and Valmet D3

### Conclusion

Valmet FlexBatch automatically coordinates data flow, resource management, and process sequencing, making complex multi-stage productions reliable and consistent. This flexible and user-friendly approach reduces the programming burden on recipe developers while supporting continuous improvement in productivity and product quality.

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Valmet is a global technology leader with over 225 years of experience, providing innovative automation solutions for process industries. In 2024, the company achieved approximately 5.4 billion euros in net sales and supports its customers worldwide with approximately 19,000 professionals.