The APACS+™ batch automation system is a flexible solution well suited for specialty chemical, pharmaceutical, food & beverage, and pulp & paper applications. By combining S88.01-based batch management with IEC 61131-3 based configuration tools, APACS+ alleviates the change management issues so prevalent in batch processes--from quick product changeovers to frequent recipe adjustments.
Reduced Engineering Costs
APACS+ provides an S88.01-based graphical process modeling tool that allows you to define recipes as equipment-independent generic processing and transfer functions. This tool allows you to break a configuration down into discrete, repeatable modules, including units, phases, and operations. The resultant model is then used to construct and manage recipes.
In contrast to custom code, process modeling provides greater flexibility and reduces dependence on system experts. It allows you to easily modify formulas, recipe procedures, or process lines without any impact on the basic control strategy. Thus, you can more easily react to dynamic factors such as new product requirements, equipment changes, and lot size fluctuations
Decreased Time-To-Market
In addition to process modeling, which helps you keep pace with the constant changes associated with an R&D application, APACS+ includes features to minimize the time needed to transfer new products from research to production. For example:
Test recipes can be run in a mode simulating the process models of various production facilities, helping you determine the most effective process lines for a particular product.
Production delays are alleviated through automatic recipe scaling, which eliminates the need to redefine ingredients and formulas.
Individual processes can be validated without necessitating revalidation of the overall process model or controller, making new recipes easy to create and maintain.
Improved Throughput
APACS+ improves throughput by minimizing production delays. Since a recipe can be easily scaled and assigned to any line containing the required process classes, you can more quickly respond to production changes. Once the production parameters are defined, APACS+ verifies bulk ingredient and equipment availability to facilitate faster throughput. APACS+ provides accurate ingredient tracking and eliminates ingredient shortages through a materials database that easily links to higher-level material management systems.
Improved Documentation
APACS+ automatically documents production history to help reduce liability and meet regulatory agency requirements. APACS+ automatically stores a comprehensive record of batch activity, including alarms, operator changes, comments process data, materials used, and materials produced. You can also incorporate electronic signatures to meet regulatory requirements for electronic batch records.