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IND780batch Basics Overview
IND780batch
Basics
Overview
IND780batch Basics Overview
Batch Control Systems - The Opportunity
Batch Control Systems - The Opportunity
Global Batch Systems Market
Global Batch Systems Market

10%

20%

Integrated Solutions Company Standards

Integrated Solutions Global Standards

IND780 Batch
IND780
Batch

Standalone Systems

Filling & Blending Hybrid (semi-automatic)

Totally Manual Blending & Batching

Batch Standalone Systems Filling & Blending Hybrid (semi-automatic) Totally Manual Blending & Batching 70%

70%

Filling & Blending Hybrid (semi-automatic) Totally Manual Blending & Batching 70% 2 Internal usage only
IND780batch – Market Opportunity
IND780batch – Market Opportunity
IND780batch – Market Opportunity ~35% North America or 1.5 Billion 70% combined totally manual & stand
IND780batch – Market Opportunity ~35% North America or 1.5 Billion 70% combined totally manual & stand

~35% North America or 1.5 Billion 70% combined totally manual & stand alone ~1.0 Billion North American batching control market

Estimate 3500 – 4000 batching systems/year in the US (IND780 Batch target market)

IND780 Batch - Purpose
IND780 Batch - Purpose

Provide a solution for applications that require:

Stand Alone operation, no PLC required

A flexible, user-defined sequence

Simultaneous multi-scale batching

Any combination of multi-material filling, manual formulation, blending, or dosing

Direct management of material delivery via high speed I/O control, with connections for up to 56 outputs

Storage of multiple formulas or recipes

Simple operational user security, track & trace, and reporting features

Follows S88 batch standards

IND780batch – Value Position
IND780batch – Value Position

More Attractive (for everyone)

- Manual, Hybrid, Auto

- Stand alone

- Single or multiple scale

- Easy to configure & use

- Multiple markets

- Entry level pricing

Batch 780 Product Attractiveness
Batch 780
Product Attractiveness

Customer Accessibility

More Accessible

- Standard channel

- Large MT customer base

- Opportunity to call:

8Competitor (RTC) 8Legacy 9215 & LynxBatch 8Upgrade 780 8New opportunity

IND780batch - What is batch?
IND780batch - What is batch?

One of the three types of manufacturing processes: Continuous, Discrete and Batch.

- According to the S88 standard, a batch process is defined as “process that leads to the production of finite quantities of materials by subjecting quantities of input materials to an ordered set of processing activities over a finite period of time using one or more pieces of equipment.”

- "Ein Prozess, welcher zur Produktion einer endlichen Quantität von Material durch die Zuführung von bestimmten Mengen von Ausgangsmaterial in einem gegebenen Ablauf von Prozessaktivitäten über eine endliche Zeitperiode unter Verwendung eines oder mehrerer Geräte führt."

- In simple terms: take some fixed amount of raw materials and do something to them to make a new material.

IND 780batch – Project Scope
IND 780batch – Project Scope

IND780batch project components

- IND780batch application firmware for the IND780 terminal

- PC Configuration Tool to support IND780batch

- Preconfigured packaged batching system

- Demonstration kit

IND780batch product offering

- IND780 panel mount or harsh enclosure, color HMI, up to 4 scales 8IND780 Manual Batch 8IND780 Automatic Batch spill only 8IND780 Automatic Batch with

- Batch application Pac field upgrade Kit-of-Parts 8Seven I-buttons

- PC Configuration Tool 8One PC Tool for all levels of IND780 Batch

- Preconfigured IND780 Packaged Batch (Single Scale) 8Automatic Batch or Automatic Batch with Q.i option

- Support materials 8Marketing program, sales tools and product demonstration kit

Q.i option - Support materials 8 Marketing program, sales tools and product demonstration kit 7 Internal
Q.i option - Support materials 8 Marketing program, sales tools and product demonstration kit 7 Internal
IND780batch – Project summary
IND780batch – Project summary

IND780batch product offering:

- IND780 panel or desktop/harsh enclosure, color HMI, up to 4 scales

8IND780 terminal with Batch-780 hardware key

- Batch application Pac Kit-of-Parts

8Upgrade of standard IND780 terminal to Batch Pac

- PC Configuration Tool

- Preconfigured Packaged IND780batch system

8Single Scale, 2 x DIO cards, 1 x ARM 100

- Demonstration kit (similar to IND 560 fill)

- Documentation:

8Batch Technical Manual 8Batch User’s Guide 8IND780 Terminal Installation Guide.

IND780batch – Product Circle
IND780batch – Product Circle
Panel Mount
Panel Mount

Hardware Security Key (I-button)

Manual, Auto, & Auto with Q.i

Security Key (I-button) Manual, Auto, & Auto with Q.i Desktop PC Based Demo with Scale Simulator
Desktop
Desktop
Key (I-button) Manual, Auto, & Auto with Q.i Desktop PC Based Demo with Scale Simulator BatchTool™
Key (I-button) Manual, Auto, & Auto with Q.i Desktop PC Based Demo with Scale Simulator BatchTool™
Key (I-button) Manual, Auto, & Auto with Q.i Desktop PC Based Demo with Scale Simulator BatchTool™

PC Based Demo with Scale Simulator

Auto with Q.i Desktop PC Based Demo with Scale Simulator BatchTool™ 780 PC Based Configuration Tool

BatchTool™ 780 PC Based Configuration Tool

Packaged IND780batch

IND780batch - Example System
IND780batch - Example System

Recipe Management

Order Management

• Equipment Management
• Equipment Management
IND780batch – Value Position
IND780batch – Value Position

Attractive Product Features

- Stand alone Batch controller for small to mid size batching operations that can benefit from having a full featured controller.

- Manual, Hybrid, & Auto phase execution capability

- Single or multiple scale (up to 4), supports both Vertical and Horizontal

Batch 780

Batching applications

- Easy configuration and use, provides “Box to Batch” functionality

- Unique capability to utilize Q.i Predictive Adaptive Control to minimize material feed variability and improve production efficiency

- Provides configurable batch solution for use across multiple batch process types.

- Can re-scale batch sizes by %, target weight amount, or ingredient amount

- Allows upgrade of current IND780 terminals with Batch application Pac

- Included PC Tool allows easy user interface to terminal for setup of material feeds, recipe entry, order creation, track and trace logging, usage reporting, and security control

- Fully documented in multiple languages and globally supported

IND780batch
IND780batch
IND780batch IND780batch is available in either a panel mount or harsh/desk mount version. Panel Mount: -
IND780batch IND780batch is available in either a panel mount or harsh/desk mount version. Panel Mount: -
IND780batch IND780batch is available in either a panel mount or harsh/desk mount version. Panel Mount: -

IND780batch is available in either a panel mount or harsh/desk mount version.

Panel Mount:

a panel mount or harsh/desk mount version. Panel Mount: - 220 x 320 x 105 mm

- 220 x 320 x 105 mm (NEMA 4X / 12, stainless steel)

Harsh/Desk Mount

x 105 mm (NEMA 4X / 12, stainless steel) Harsh/Desk Mount - 200 x 299 x

- 200 x 299 x 235 mm (IP69K, stainless steel)

4X / 12, stainless steel) Harsh/Desk Mount - 200 x 299 x 235 mm (IP69K, stainless
Packaged IND780batch – Specifications
Packaged IND780batch – Specifications
IND780 Panel Color - 1 Analog Load Cell Scale card - 2 Discrete I/Os (8in
IND780 Panel Color
- 1 Analog Load Cell Scale card
- 2 Discrete I/Os (8in / 8out)
Enclosure 16”x20”x8” NEMA 4 (Mild Steel)
- 24VDC Power supply
- 24VDC or 120VAC interface
- 3 User input buttons
8
E-stop
8
Start/Resume
8
Pause/Abort
- 1 Attention Light
- 10 Materials interlocked with fast Final Control
Element on Analog Scale Card
- 1 Auxiliary/11 th Material
- 1 Dump to Empty Material
- 1 ARM 100 (additional 4/6 I/O)
- Replacement Solution for Legacy MT batching
products
No UL or other agency approvals
- All components UL and CUL/CSA approved
batching products No UL or other agency approvals - All components UL and CUL/CSA approved 1
Packaged IND780batch – Example
Packaged IND780batch – Example
Packaged IND780batch – Example 1 4 Internal usage only
Packaged IND780batch – layout
Packaged IND780batch – layout
Packaged IND780batch – layout 1 5 Internal usage only
Capabilities – Communications & I/O Options
Capabilities – Communications & I/O Options

Standard (on board)

- Ethernet 10/100baseT

- USB Master (Includes support for external keyboard)

- RS232 & RS232/422/485 ports

Serial (additional option board)

& RS232/422/485 ports Serial (additional option board) - Single port up to 115K Baud - RS232
& RS232/422/485 ports Serial (additional option board) - Single port up to 115K Baud - RS232

- Single port up to 115K Baud

- RS232 or RS422 / RS485

- Two cards per unit (total of 4 ports)

Discrete I/O (additional option board)

- Relay I/O

- 4 inputs & 4 outputs per option card

- Two cards per unit

Remote Discrete I/O

(ARM100)

- 4 inputs, 6 outputs (each)

- Up to 8 ARM-100 modules may be connected to the IND780 terminal

4 inputs, 6 outputs (each) - Up to 8 ARM-100 modules may be connected to the
4 inputs, 6 outputs (each) - Up to 8 ARM-100 modules may be connected to the
4 inputs, 6 outputs (each) - Up to 8 ARM-100 modules may be connected to the
4 inputs, 6 outputs (each) - Up to 8 ARM-100 modules may be connected to the
IND780batch - Control Panel
IND780batch - Control Panel

The IND780batch control panel

Standard IND780 menu tree automatically expands with Batch-780 option

- Option enabled with Batch hardware key (I-button)

Configure scales and terminal settings from front display

Batch-780 option only

key (I-button) Configure scales and terminal settings from front display Batch-780 option only 1 7 Internal
IND780batch
IND780batch

IND780batch Terminal:

- Contains / controls the physical equipment

- Stores / executes the recipe

- Stores batch history data

BatchTool 780, PC Tool:

- Creates & remotely stores system configuration

8

Equipment

8

Recipes

- Loads configuration in terminal

- Archives batch history data

- Comes standard with every Batch- 780 system

- One PC Tool can manage any number of IND780batch terminals.

with every Batch- 780 system - One PC Tool can manage any number of IND780batch terminals.
with every Batch- 780 system - One PC Tool can manage any number of IND780batch terminals.
IND780batch
IND780batch

IND780batch Basics:

- Batch-780 is a stand alone batch control, that does not require connection to a PLC or DCS.

- Batch-780 can control 1 to 4 scales simultaneously

- Batch-780 can handle up to 999 materials, with up to 28 being automatic materials

- Batch-780 complies with the ISA S88 batch standard to assure a consistent protocol for batch operations

- Batch-780 can store up to 1000 recipes with each recipe containing 99 steps.

- Batch-780 has intelligent power loss recovery

- Batch-780 can support up to 8 ARM-100 modules, giving a total of 40 discrete inputs and 56 discrete outputs for flexible system integration

- Batch-780 has standard multi level security – Operator, Supervisor, Administrator, Maintenance

Marketing Review – Beta sites
Marketing Review – Beta sites

Georgia Pacific, Hawthorne, FL

- 9215 legacy replacement

- 5-auto materials plus hand add

- Packaged IND780batch, Single Scale, Auto

- Started up week of March 7 th

- A few minor code changes required, no other operational issues reported.

- Batching Glue for plywood

minor code changes required, no other operational issues reported. - Batching Glue for plywood Internal usage
minor code changes required, no other operational issues reported. - Batching Glue for plywood Internal usage

Internal usage only

minor code changes required, no other operational issues reported. - Batching Glue for plywood Internal usage

20

Marketing Review – Beta sites
Marketing Review – Beta sites

Plochman’s, Chicago, IL

- Wanted to get away from PLC based system

- 1 x Packaged Batch Auto and 1 x Manual station

- All equipment is installed, but not yet being utilized.

HTC, Sweden

is installed, but not yet being utilized. HTC, Sweden - 2 x Manual systems - New

- 2 x Manual systems

- New to Batch systems, using a paper based solution

- Installed in February 2011, running well

New to Batch systems, using a paper based solution - Installed in February 2011, running well
New to Batch systems, using a paper based solution - Installed in February 2011, running well
Marketing Review – Beta sites
Marketing Review – Beta sites
Marketing Review – Beta sites Schulze & Burch Biscuit Co., Chicago, IL - 9215 legacy replacement,

Schulze & Burch Biscuit Co., Chicago, IL

- 9215 legacy replacement, food products

- Automatic System with 12 materials + hand adds

- Equipment Installed and functionally tested February 2011, start-up delayed by customer

Batch Auto system installed on a Truck scale application (Forbo Flooring)

Batch Auto with 2 channels of Q.iMPACT installed on a bag filling system, running well.

IND780batch
IND780batch

IND780batch Operation (Phase execution types):

- Manual mode:

8The recipe will progress from one step to another manually, requiring operator input for each step. In manual mode the operator can choose which step of the recipe he wishes to run.

- Semi-Automatic Mode:

8The recipe will automatically progress from one step to another, but must press “start” to begin the next recipe step.

- Automatic Mode:

8The recipe will progress from step to step as defined by the recipe, no operator acknowledgement is required unless called for in the recipe.

IND780batch – Product Features
IND780batch – Product Features

Operational views:

- A1 … Order View (default view for IND780batch)

- A2 … Recipe View

- A3 … Equipment View

- A4 … Scale View (default view for standard terminal)

Views modes (new in 7.1.xx):

- View by equipment 8Operator manually controls what view is used

- View by phase 8IND780batch automatically determines what equipment detail view to show based on which phases are currently running

2424

Internal usage only

IND780batch – Product Features A1… Order View -Displays all open orders
IND780batch – Product Features
A1… Order View
-Displays all open orders

A2 … Recipe View

-Displays current recipe overview and status information

- Displays current recipe overview and status information … Recipe Details - Displays recipe details 2

… Recipe Details

-Displays recipe details

2525

current recipe overview and status information … Recipe Details - Displays recipe details 2 5 2
current recipe overview and status information … Recipe Details - Displays recipe details 2 5 2

Internal usage only

IND780batch – Product Features
IND780batch – Product Features

A3… Equipment View

-Displays equipment status -During recipe execution, the equipment details softkey can be pressed to see special detail views

details softkey can be pressed to see special detail views A4 … Scale View - Displays

A4 … Scale View

-Displays scale home page and provides access to setup & other softkey functions

2626

View - Displays scale home page and provides access to setup & other softkey functions 2
View - Displays scale home page and provides access to setup & other softkey functions 2

Internal usage only

IND780batch
IND780batch

IND780batch Material Transfer Types:

-Manual:

8The operator must control the transfer of material into the scale. In a Manual Material Transfer the operator can see the SmartTrac display in the Equipment Detail View screen. 8The manual material transfer feed algorithms that can be selected are:

- Hand Add, Hand Add LIW, Hand Add Dump to Empty, & Pre-Weigh

Add, Hand Add LIW, Hand Add Dump to Empty, & Pre-Weigh SmartTrac display with color graph

SmartTrac display with color graph to allow operator to see when material is within the tolerance range

display with color graph to allow operator to see when material is within the tolerance range
display with color graph to allow operator to see when material is within the tolerance range
display with color graph to allow operator to see when material is within the tolerance range
display with color graph to allow operator to see when material is within the tolerance range
display with color graph to allow operator to see when material is within the tolerance range
display with color graph to allow operator to see when material is within the tolerance range
display with color graph to allow operator to see when material is within the tolerance range
IND780batch
IND780batch

IND780batch Material Transfer Types:

-Automatic:

8Batch-780 will control the material transfer automatically by opening of feed valves or discharge valves from the scale. In Automatic Material Transfer the Operator can see the tank display as depicted in the screen shot below. This screen is the Equipment detail screen. 8The Automatic material transfer feed algorithms that can be selected are:

- Gain in Weight (GIW), Loss in Weight (LIW), Dump to Empty

that can be selected are: - Gain in Weight (GIW), Loss in Weight (LIW), Dump to
that can be selected are: - Gain in Weight (GIW), Loss in Weight (LIW), Dump to
that can be selected are: - Gain in Weight (GIW), Loss in Weight (LIW), Dump to
IND780batch
IND780batch

IND780batch Material Transfer Types:

-Automatic with Q.iMPACT:

8Batch-780 will control the material transfer automatically utilizing the K1/K2 control algorithm by opening of feed

valves or discharge valves from the scale.

Q.iMPACT the Operator can see the tank display as depicted in the screen shot below.

In Automatic with

8The Automatic with Q.iMPACT material transfer feed algorithms that can be selected are:

- K1 Gain in Weight (GIW), K1 Loss in Weight (LIW), K2 Gain in Weight (GIW), K2 Loss in Weight (LIW), Dump to Empty

Weight (GIW), K1 Loss in Weight (LIW), K2 Gain in Weight (GIW), K2 Loss in Weight
Weight (GIW), K1 Loss in Weight (LIW), K2 Gain in Weight (GIW), K2 Loss in Weight
Weight (GIW), K1 Loss in Weight (LIW), K2 Gain in Weight (GIW), K2 Loss in Weight

Internal usage only

IND780batch
IND780batch

IND780batch

Batching Types:

- Batch-780 can do both Vertical and Horizontal batching

Vertical Batch

3 3 3 2 2 2 1 1 1
3
3
3
2
2
2
1
1
1

Horizontal Batch

2 3 1 3 1 2
2
3
1
3
1 2

- A unit procedure can be created in a vertical batch to carry out a special recipe sequence.

Recipes

- The terminal can store up to 1000 master recipes, with each recipe containing 99 phase steps.

- Operator can rescale the control recipe in the terminal for a particular order:

8By percentage, target value, or single ingredient amount

- Control recipes can be executed:

8By operator, discrete input or shared data

IND780batch
IND780batch

Reporting

-Configuration Reports

8Terminal List, Equipment Module List, Control Module List, Material Path List, Master Recipe List, and Master Recipe Details

-Production Reports

8Batch Details, Batch History, Batch History Completed/Failed, Equipment Statistics, Material Statistics, Recipe Statistics, Order List

-Audit Trail Reporting

8Material Lot Tracking 8Audit Log, Change log, Error Log 8Tool Change Log

Local printing

- Batch transaction, batch summary and audit log.

IND780batch
IND780batch

Example Batch History Report

IND780batch Example Batch History Report 3 2 Internal usage only
IND780batch
IND780batch

Example Batch Details Report

IND780batch Example Batch Details Report 3 3 Internal usage only
IND780batch
IND780batch

Example Master Recipe Details Report

IND780batch Example Master Recipe Details Report 3 4 Internal usage only
IND780batch
IND780batch

Batch-780 System Benefits

-Adhering to S88 Batch standard allows a common set of criteria to be followed with regards to:

8Tracking information 8Recovery from abnormal events 8Separating equipment from recipes 8Data collection 8Modular configuration

8Validation

-These features will provide the following benefits for the Batch user:

8Reduced Batch cycle times 8Improved batch consistency 8Reduced raw material loss 8Reduced time to change from one recipe to another 8Reduced number of manual operations 8Improved equipment utilization 8Reduced capital investment

IND780batch – Support Tools
IND780batch – Support Tools

IND780 Q.i/Batch dashboard

- Firmware updates

- Back up and Restore

- Data monitor

- Works with Batch 780 and Q.iMPACT

- Feed History Record recording

- Auto archiving of Feed History Records

- Support Report generation

Mettler-Toledo InSite™ service tool:

- Scale setup/calibration

- Backup and restore

Mettler-Toledo InSite™ service tool: - Scale setup/calibration - Backup and restore 3 6 Internal usage only
Mettler-Toledo InSite™ service tool: - Scale setup/calibration - Backup and restore 3 6 Internal usage only
IND780batch- Marketing Launch Materials
IND780batch- Marketing Launch Materials
IND780batch- Marketing Launch Materials IND780batch Launch Letter IND780batch Data Brief Marketing Material and supporting

IND780batch Launch Letter

Marketing Launch Materials IND780batch Launch Letter IND780batch Data Brief Marketing Material and supporting

IND780batch Data Brief

Marketing Material and supporting documents are available in the BUSI Terminals SharePoint site or at the Batch FTP site located at:

http://collaboration.mt.mtnet/team/wiw/BU-

SI/PLM/780batch/Shared%20Documents/Forms/AllItems.aspx

ftp://ftp.usa.mt.com/pub/indmkg/IND780_Batch/Index.htm