Batch process master recipe

For the planning of a multipurpose plant one has to map the structure of a master recipe to the detailed device structure of the plant with regard to a given time in the future. This process can be done automatically, e.g., with the SAP ERP system where it is called convert. The result is a process order as a concretization of a master recipe. A process order tells the production operator at which time and on which device a given batch production step has to be executed. This simple conversion can result in a situation where a selected device is already allocated to a different process order at the given time, thus the production plan may not be feasible. 

Sufficient adaptation of the properties of the process cell equipment to ensure the correct processing of the batch, by marrying the master recipe information with the functionality of the specific set of process cell equipment. 

The master recipe is essential, as without it, control recipes cannot be created, hence no batch processing. 

General and site recipes are non-equipment dependent and describe the technique of the process, or how to do it in principle, they may however, specify when known, data that may be required for the equipment, for example, pressure requirements. The general recipe is defined at the level of the enterprise, whilst the site recipe is specific to a particular site. Master and control recipes describe the task, i.e. how to do it with actual resources. The master recipe is the required recipe as without it no control recipe can be created and therefore no batches can be produced. 

There should be a master batch record document from which each individual batch record is generated. This insures that each lot made is manufactured following the same recipe. When the lot specific batch record is issued, there must be a check to assure that the issued batch record is specific for a single unique batch number and the instructions are identical to the master batch record document. The lot specific record will have the signature of those individuals who performed critical processing steps in the manufacturing process and those who performed any in-process testing. 

The ground is laid for industrial use of man-made cellulose fibers for reinforcing a series of thermoplastics. Specific recipes, including processing aids, stabilizers, color master batches, etc., remain to be developed for possible applications in various sectors of the plastics industry. 

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