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Home > Posts > Real-Time Analytics for Batch Processes
June 06

Real-Time Analytics for Batch Processes

Keywords: Real-Time Batch Analytics, Batch Analytics, Brewing, Lubrizol.

Companies that utilize batch manufacturing processes for specialty chemicals, food, pharmaceuticals, biotech products and other products can utilize data that are already being collected to make real-time decisions and take appropriate actions. Real-time batch analytics can help companies gain a better understanding of their processes, minimize variations, and know where to make improvements to the process instantaneously.

Historically, batch processes have been difficult to control and analyze because each batch is unique: batches are not the same length; time lags differ; raw materials can differ, and there are often differences in equipment, operating conditions, and process activity. Advanced batch controls can be complex. Understanding how these variations impact batch quality while the batch is running can provide enormous benefits.

Real-Time Batch Data Analysis
Manufacturers use batch analytics software to compare batches to help un-cover potential problems in real time. One batch analytics solution developed by Emerson Process enables users to compare ideal, "golden" batches to other batches to help better understand how variables affect the current batch. The company calls this "dynamic time warping" (DTW). DTW aligns the data and can compare many batches' parameters and accommodate for variable timing differences. The technology helps align the data accurately between batches and match parameters from historical batch data to the variations found in the live batches.

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