Glossary · Control theory and process control
Batch control
Also known as: Batch process control, Batch automation
German: Chargenregelung
In process automation, batch control is the control of processes that produce finite quantities of material by subjecting inputs to an ordered set of processing activities over a finite time, structured in ISA-88 / IEC 61512-1 by physical, procedural and recipe models.
- Control theory
- Process industry
- Standards
In one sentence
Batch control runs processes that make finite quantities of product through ordered steps, structured by the ISA-88 models and recipes.
Example
In a pharmaceutical plant, the batch control system executes the control recipe for one batch of granulate: charge, mix, heat, dry and discharge, each as a phase on a unit.
How it applies
- Engineering: ISA-88 separates equipment control (phases, equipment modules, units) from product-specific Recipe content. This separation lets a plant make new products by writing recipes instead of changing control code.
- Operation: Operators start batches, confirm manual steps and respond to prompts. Each action and deviation is recorded for the Batch report.
- Compliance: In regulated industries, batch records support release decisions under Good manufacturing practice (GMP); electronic records then have to meet data integrity requirements.
- Documentation: Use ISA-88 terms consistently (procedure, unit procedure, operation, phase) and keep them aligned with the terms on the HMI. Operator instructions for manual phases should match the prompts in the control recipe.
Batch control vs. continuous control
Continuous control keeps a process at a steady operating point with material flowing continuously. Batch control moves a defined quantity of material through a sequence of states and ends when the batch is complete.