Batch Process Design and Build

Batch process is more than recipe management; it requires extensive process knowledge and expertise to ensure product quality and repeatability. Optimation’s batch experts draw on decades of experience in process engineering, mechanical engineering, chemical engineering and controls engineering. 

 

Batch Process Design

Optimation’s technical staff will work with you to determine your particular process design parameters and constraints, seamlessly integrating new process design with your existing production process. Work with us for process analysis, revealing improvements and equipment upgrades for more profitability. Grow your business by working with our team to scale up your existing processes to add capacity, driving down utilities and maintenance costs to improve efficiency and profitability.

 

Process Equipment Design

  • Reactors
  • Mixing and mixers
  • Propellers
  • Reactant metering
  • Dispersion equipment
  • Compounding equipment
  • Materials of construction selection
  • Sanitary piping design
  • Clean-in-place (CIP) design
  • Filtration
  • Pump selection
  • Heat Exchange systems
  • Vacuum systems
  • Custom skids prefabricated and tested

Batch Process Control and Recipe Management

Quality and repeatability come from control – controlling how you add your ingredients, how they’re mixed, and how the product is delivered. A well-controlled batch process ensures you have the same product every time. Optimation’s software, controls, electrical and instrumentation engineers excel in keeping batch processes in control and monitored, providing required data archival and retrieval functionality.

Application experience includes:

  • Instrumentation specifications
  • Batch recipe control
  • S88 Standards
  • Supervisory Control and Data Acquisition (SCADA)
  • Distributed Control System (DCS) Integration
  • DCS Upgrades
  • Programmable Logic Controllers (PLC)

 

Clean-in-Place (CIP)

Optimation includes CIP considerations during batch process design. We have experience in a variety of CIP techniques, such as solvents, bases, and pigging, among others.

 

Build and Installation Services

In contrast to many vendors who may offer only the mechanical and process or only the controls services, Optimation is a single source provider for the entire project. Our skilled tradesmen work with our designers and engineers to fabricate custom equipment for your batch process. Our rigging specialists and millwrights are qualified personnel with experience in handling and installing process equipment.

Example skills:

  • Passivating
  • Grinding
  • Weld polishing
  • Orbital welding
  • R & U Stamp certifications for pressure vessel repair and fabrication

S88 and 21 CFR Part 11

Optimation provides engineering services for S88 and 21 CFR Part 11 implementations. Our engineers specializing in batch process and control systems have experience with S88 and 21 CFR Part 11 the standard dating back to their inception/approval. We have implemented it on a wide variety of DCS and PLC platforms. Our engineer’s full range of project services expands across several industries including chemical, food and beverage and life sciences/pharmaceuticals.

Click here to learn more.