Batch Plus®
A recipe-based modeling technology for the batch industries used to develop a process and generate required documentation from early route selection to full scale manufacturing. Batch Plus facilitates sharing of information across the company by providing a standard approach for creating and managing process information throughout the development workflow.
The Challenge: More with Less Today’s fast-paced specialty chemical and pharmaceutical businesses require rapid and effective development of new products. The goal of process development teams is to supply enough product on time and on spec. The most successful organizations improve productivity while identifying potential processing difficulties early enough to avoid serious costs and delays. Aspen’s Batch Process Development Solutions are created specifically for getting the most out of process development activities in the batch processing industries.
“Aventis is committed to discovering, producing and marketing innovative pharmaceuticals. Batch Plus and Aspen Plus will assist us in accelerating the process development and production of these pharmaceuticals by reducing our time-to-market, improving quality and avoiding information losses. We believe that AspenTech’s software will be critical in helping us to rapidly learn more about processes and accelerate process development.” Dr. Thomas Tauchnitz Head of Process Development Engineering Aventis
The Opportunity: Recipe Modeling with Batch Plus Batch Plus is a lifecycle solution designed to support the work process and information requirements of the batch processing industries, from R&D through production. As soon as a molecule leaves the lab bench for reproduction in pilot and manufacturing facilities, Batch Plus is used to build information regarding the process within a recipe model. Instead of depending on spreadsheets and text documents to relay and replicate recipe information across the operation, Batch Plus allows chemists and chemical engineers to build upon a single description or model of the process. This recipe is reutilized to automatically generate required process documentation, dramatically reducing the effort for generating tech transfer packages. Implicit information buried in spreadsheet formulas turns into explicit information, by standardizing the assumptions and information involved with process development. Communication between colleagues, suppliers and clients is greatly enhanced with information that is relayed across a common infrastructure.
With a recipe model, you can quickly visualize the critical issues involved in a process and select the best development alternatives given available equipment, materials, and regulatory constraints. Ask the right questions at the right time: • Can we deliver a particular product in the desired quantity and time? • What is the limiting vessel? • How can I increase yield and reduce emissions? • Is there a way of reducing the number of steps? • What are our costs and can they be reduced?
“In one example, Batch Plus allowed us to identify that in a single process we could double batch size without major investments.” Dr. Michael Grund Head of Department, Central Process Development – Engineering Merck KGaA
Benefits Offered by Batch Plus Market leaders in the batch industries tell us that Batch Plus delivers tremendous value. From experience customers can: • Increase Productivity – Provide consistency and clarity in assumptions, data, documentation and results – Input once, reuse data, automate documentation – Arrive at earlier go/no-go decisions – Reduce the number of trial-and-error batches – Bring people ‘up to speed’ more quickly • Reduce Capital and Operating Costs – Reduce over-design – Increase yield, purity, product and solvent recovery – Reduce energy use, excess raw material charges and wastes – Improve asset utilization
Batch Plus Applications In the laboratory: Compare process alternatives, evaluate ‘make versus buy’ decisions and select synthetic routes for new molecules. With minimal process information, conduct mass balances and obtain quick cost estimates. Use molecular structures in reactions for physical property estimation and detailed kinetic reaction modeling. In early process development: Develop the synthetic route coming from the laboratory and map conceptual processes to recipes. Batch Plus quickly evaluates process alternatives, generates material balances, performs cycle time calculations and develops cost estimates during the early stages of process definition. Screen new processes more quickly and efficiently to identify those that are most cost-effective. In the pilot plant: Develop kiloscale processes from bench-scale recipes. Perform ‘process-fit’ analysis, whereby a process is matched with the ‘best’ possible site. Automatically generate plant operating instructions and process flow diagrams, as well as perform advanced emission calculations from a single recipe. These applications reduce time-to-market for process scale-up and maximize return on assets for existing manufacturing facilities.
In process engineering: Scale-up the pilot process to fullscale and determine where to manufacture the new process. Perform an economic analysis of the process and use the process model to design the needed waste treatment and utility systems. Batch Plus calculates peakload requirements on shared resources (e.g., utilities, waste treatment, raw materials and labor) to avoid over-sizing utilities and enable better planning of capacity expansions.
In production: Eliminate bottlenecks at existing plants and investigate capacity expansions. Simulate single- or multi-product campaigns and calculate in-plant emission profiles. Batch Plus identifies time- and size-limiting equipment to evaluate alternatives for increasing throughput. The ability to incorporate actual plant data from a data historian like InfoPlus.21® (AspenTech’s Information Management System for real-time manufacturing processes) allows users to validate the process model or use a validated model to troubleshoot problem batches.
Aspen’s Batch Process Development Solution Batch Plus is a component of Aspen’s Batch Process Development solution which consists of the following products and services: • UNIT OPERATIONS MODELS that allow you to focus on specific problem areas that can be solved using rigorous modeling tools. (e.g. BatchCAD, BatchSep, Process Tools™) • REFERENCE LIBRARIES that provide expert information on solids and separation processes. (e.g. Process Manual) • Accurate and consistent THERMOPHYSICAL PROPERTIES with web and Excel interfaces that simplify estimation and data regression. (e.g. Aspen Properties™) • EXPERT SERVICES team that can provide assistance with custom applications, configuration and implementation activities
The Goal: Improved Productivity and Reduced Costs Utilize the wealth of process knowledge generated by your company to your advantage. Leverage information technology to automate routine tasks and free resources to deliver value. BatchPlus will enable your team to create more profitable processes on spec and on time. Let us share our experiences with you. We would be happy to schedule an informal session to answer questions and discuss how we can help.
“What we benefited from Batch Plus was a unified data transfer, unified communication tool, and a unified business model.” Dr. Lukas Utiger Head of Business Unit, Exclusive Synthesis Lonza Group
AspenTech: A Tradition of Innovation Leading companies rely on AspenTech’s solutions for batch process development, including Aventis, Cambrex, DuPont, Eli Lilly, GlaxoSmithKline, Lonza, and Merck KGaA. For more information, please contact your local AspenTech sales office or e-mail
[email protected]. Aspen Technology Inc.’s proven, integrated software and rapid implementation services enhance the efficiency and profitability of process companies. AspenTech’s process design software optimizes process designs to maximize lifecycle returns. AspenTech’s manufacturing/supply chain software harmonizes production, inventory, demand, and delivery to improve operating margins. Together, these offerings create an integrated solution – enterprise operations management (EOM) – that transforms enterprise-wide operating performance.
“We used Batch Plus on a new product to scale-up from lab-scale in our semiworks. It allowed the scale-up to be done very quickly. To us it is strategically important to reduce timeto-market. Batch Plus enabled faster conceptualization of the new process and even facilitated generation of operating instructions, raw materials ordering and hazard analysis. It helped us meet our tight timetable.” Ken Mersman DuPont Agricultural Enterprise
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Copyright © 2004. AspenTech, Batch Plus, InfoPlus.21, BatchCAD, BatchSep, Process Tools, Process Manuals, Aspen Properties, and the Aspen leaf logo are trademarks or registered trademarks of Aspen Technology, Inc., Cambridge, Massachusetts USA. All rights reserved. All other brand and product names are trademarks or registered trademarks of their respective companies. PB 205 07/13/04
