The integration of DCS (Distributed Control System) and Batch systems serves as the standard solution for recipe-driven production in process industries, particularly suitable for industries requiring batch control such as pharmaceuticals, food and beverage, and fine chemicals.
Application Area
Pharmaceuticals: Blood Products, Chemical Pharmaceuticals, Cell Therapy, Gene Therapy, Antibody Products, Vaccine, Traditional Chinese Medicine
Chemicals: Flavors & Fragrances, Catalysts, Adhesives, Lubricants, Coatings & Inks, Electronic Chemicals, New Energy Materials
Food & Beverage: Dairy Products, Infant Formula, Health Products, Liquor, Cosmetics & Personal Care Products, Seasonings, Beer
Typical System Architecture
System Function Introduction
The DCS system provides:
Basic continuous control (e.g., PID regulation), equipment-level interlocking, real-time data acquisition, and human-machine interface (HMI).
It supports multiple network protocols: Industry ethernet, profiNET, Profibus-DP, PA bus, ISP bus, TCP/IP, etc.
It supports multiple functions: route control, batch control, process history data server, web server
It supports multiple network structures: line, star, ring or combination structure
The Batch system provides:
Recipe management (master recipes, control recipes)，Batch tracking and traceability，Phase logic control (Phase Logic)，Production order execution
Key Components of SIMATIC Batch
SIMATIC Batch Workflow
Hierarchical Recipes according ISA-88.0
Uses the physical and procedural models of ISA-88 for the utilization of plant equipment
Application Example 1: CFC+SFC+Batch
Hardware : CPU410-5H+ES+OS
Software: Siemens PCS7 + Batch
Benefits:
Flexible configuration and modular architecture
Perfectly integrated with the PCS7 sequential control software SFC to achieve flexible formulation of actions and parameters
Minimize cleaning/preparation time during batch switching
Optimization of the number of parallel batches
Implemented full batch lifecycle management from raw materials to finished products
Simultaneously maintaining the precise control capability of DCS over underlying equipment
It is the core technical solution for achieving flexible production in batch process industry
Application Example 2: PCS7+Batch+Audit Trial+SIMATIC IT eBR (Opcenter Execution Pharma)
Manage Audit Trial:
Production order from EBR：
Hardware: CPU410-5H+ET200SP HA
Software: SIMATIC PCS7+Batch+SIMATIC IT EBR (Opcenter Execution Pharma)
Benefits：
Easy creation of recipes through graphical user interface
