Perfect Batch

Perfect Batch is an Industrial AI and manufacturing analytics solution that connects to your existing batch-related process data. It identifies your ideal batch profile and transforms your raw data into actionable intelligence. Through Perfect Batch, you can better identify deviations, reduce waste, and ensure batch-to-batch consistency—helping you replicate your "golden batch" every time.

The ROI for Perfect Batch is realized through exposing and capitalizing on a batch system’s hidden capacity. In doing so, many customers see significant reductions and improvements in waste, cycle times, and rework. Some find that the solution pays for itself by preventing just a few off-spec batches per year. 

Perfect Batch is designed for any industry that relies on batch manufacturing processes. This includes, but is not limited to, Pharmaceuticals, Food & Beverage, Specialty Chemicals, and Consumer Packaged Goods (CPG).

Traditional systems typically use only process control data and are set at a fixed point in time. They cannot respond to variant conditions or account for additional parameters. Perfect Batch differs in three material ways: 

1. It can include all material additions, recipe data, yield data, and quality data.

2. It uses machine learning to establish a dynamic ‘perfect profile’ based on all factors that affect a batch run, one that changes as relevant production variables do.

3. It provides active recommendations to operators on what’s required to maintain optimum performance. Perfect Batch can forward those same recommendations to your HMI system. 

The solution is primarily targeted at the following roles:

• Plant Managers and Directors of Operations: They use it to identify hidden capacity (e.g., bottleneck time), compare line performance, reduce lost production, and improve overall plant efficiency (OEE).

• Quality Assurance (QA) Managers: They benefit from advanced quality analytics and full genealogy tracking, which ensures specifications are met and makes audit preparation painless.

• Continuous Improvement and Process Engineers: They use process and timing conformance metrics generated by TwinThread models to pinpoint where and when deviations may occur, enabling them to identify root causes and optimize processes.

• Operators: They receive real-time recommendations on active batches, understanding what is going well, what is abnormal, and what adjustments are needed.

• Simple Batch is for sequential processes on a single production line. It's designed for rapid deployment to identify timing and process parameter deviations.
• Complex Batch is for regulated environments and operations where a batch moves across multiple pieces of equipment on multiple separate lines. It offers automated ISA88 modeling, full material genealogy, yield tracking, and advanced quality analytics for comprehensive compliance and process control.

• If your process is a straightforward sequence of steps (e.g., mix, heat, cool) on one primary piece of equipment, Simple Batch is the perfect starting point.

• If you operate in a regulated industry (like Pharma), need to track materials for compliance, or have batches that involve multiple units with overlapping phases, you may need Complex Batch.

Getting started involves connecting your existing systems (such as historians, SCADA, or MES) using the TwinThread agent.

• For Complex Batch: Users go through a Data Source Setup wizard in the Launchpad, select their batch vendor, enter their credentials, and install the agent software. The system then interrogates past execution data to automatically build out the digital twins and apply the models in a matter of hours.
• For Simple Batch: Because it does not connect directly to an S88 batching system, it is designed for rapid deployment via straightforward manual configuration. This is a stepped process carried out by various model setup Wizards.