ProSensus understands batches: We have analyzed over 50 different batch processes, and have tackled many complex issues with regards to data organization, alignment, analysis, monitoring, prediction, optimization and control.
A batch process is any process with a start and end point and some time evolution of the variables in between. Data from batch processes is more complex to analyze than data from continuous processes due to the time evolution aspect. Batch trajectory data has 3 dimensions (the number of batches, the number of variables and the number of time points in each batch) and must be unfolded into 2 dimensions prior to analysis.
Furthermore, some batches take less time to complete due to raw material variations, environmental and equipment factors. Therefore the batch trajectory data needs to be properly aligned to facilitate a meaningful analysis.
Data Organization, Alignment, and Analysis
ProMV uses batch-wise unfolding to organize trajectory data and the batch alignment tool provides state-of-the-art methods for aligning batches that progress at different rates. Specifically, we added dynamic batch alignment in ProMV v12.08. This allows synchronization with a reference batch across all trajectory variables using an innovative optimization approach. Use ProMV to analyze historical batch data:
- Which batches were different and why
- Which variables have the most impact on the final product quality
Batch Monitoring & Prediction
ProBatch Online is a powerful tool for online batch monitoring; it makes continually-updated predictions of the final product quality while the batch is progressing. This allows you to:
- Cancel the batch before it begins if the model indicates that the raw material properties are too far from their typical values
- Monitor the batch for abnormal behaviour as it progresses and diagnose the reasons for any deviations
- Estimate the time required to complete the batch
- Decide as soon as the batch completes whether it should be released or held, ahead of the lab results
Online monitoring is great, but if you can see that a batch is likely to produce out-of-spec product, you would ideally like to take corrective action. ProBatch Control gives you all the benefits of ProBatch Online, but goes one step further to automatically compensate for variations within each batch without the need for manual operator intervention.
ProSensus offers consulting services to help you optimize your batch processes. Using multivariate models of your historical batch data, we can determine the optimal initial conditions and time-varying trajectory shapes that will achieve a desired set of finished product properties. Optimization techniques can also be used to scale-up processes and transfer them or to align product quality between manufacturing sites.
Want to learn more about batch analysis? Check out our upcoming courses in multivariate batch analysis.