IND780batch

Basics Overview

Batch Control Systems

Global Batch Systems Market 10% 20%
IND780 Batch
Integrated Solutions Global Standards

- The Opportunity

Integrated Solutions Company Standards

Standalone Systems

Filling & Blending Hybrid (semi-automatic)

70%

Totally Manual Blending & Batching

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IND780batch Market Opportunity

~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)
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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

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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

Product Attractiveness

Batch 780

More Accessible

Standard channel Large MT customer base Opportunity to call: 8Competitor (RTC) 8Legacy 9215 & LynxBatch 8Upgrade 780 8New opportunity

Customer Accessibility

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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 Quantitt von Material durch die Zufhrung von bestimmten Mengen von Ausgangsmaterial in einem gegebenen Ablauf von Prozessaktivitten ber eine endliche Zeitperiode unter Verwendung eines oder mehrerer Gerte fhrt." and do something to them to make a new material.
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- In simple terms: take some fixed amount of raw materials

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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 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
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IND780batch product offering

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 Users Guide 8IND780 Terminal Installation Guide.

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IND780batch Product Circle

Hardware Security Key (I-button)
Manual, Auto, & Auto with Q.i

Panel Mount

Desktop

BatchTool 780 PC Based Configuration Tool Packaged IND780batch

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PC Based Demo with Scale Simulator

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IND780batch - Example System

Recipe Management Order Management Equipment Management

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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
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Internal usage only

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

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

stainless steel)

Harsh/Desk Mount

- 200 x 299 x 235 mm (IP69K, stainless

steel)

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Packaged IND780batch Specifications

IND780 Panel Color - 1 Analog Load Cell Scale card - 2 Discrete I/Os (8in / 8out) Enclosure 16x20x8 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/11th Material 1 Dump to Empty Material 1 ARM 100 (additional 4/6 I/O) Replacement Solution for Legacy MT batching products All components UL and CUL/CSA approved

No UL or other agency approvals

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Packaged IND780batch Example

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Packaged IND780batch layout

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Capabilities Communications & I/O Options

Standard (on board) - Ethernet 10/100baseT - USB Master (Includes support for Serial (additional option board) - Single port up to 115K Baud - RS232 or RS422 / RS485 - Two cards per unit (total of 4
ports) external keyboard) RS232 & RS232/422/485 ports

Discrete I/O (additional option board) - Relay I/O - 4 inputs & 4 outputs per option Remote Discrete I/O (ARM100) - 4 inputs, 6 outputs (each) - Up to 8 ARM-100 modules may
be connected to the IND780 terminal
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Internal usage only

card Two cards per unit

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

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Internal usage only

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 Batch780 system - One PC Tool can manage any number of IND780batch terminals.
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Internal usage only

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
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Internal usage only

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 7th A few minor code changes required, no other operational issues reported. Batching Glue for plywood

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Internal usage only

Marketing Review Beta sites

Plochmans, 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 - 2 x Manual systems - New to Batch systems, using a paper based

solution Installed in February 2011, running well

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Internal usage only

Marketing Review Beta sites

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.

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Internal usage only

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.

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Internal usage only

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

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Internal usage only

IND780batch Product Features

A1 Order View
- Displays all open orders

A2 Recipe View
- Displays current recipe overview
and status information

Recipe Details
- Displays recipe details

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Internal usage only

IND780batch Product Features

A3 Equipment View
- Displays equipment status - During recipe execution, the
equipment details softkey can be pressed to see special detail views

A4 Scale View
- Displays scale home page and
provides access to setup & other softkey functions

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Internal usage only

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

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Internal usage only

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

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Internal usage only

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

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Internal usage only

IND780batch IND780batch
Batching Types: - Batch-780 can do both Vertical and Horizontal batching
Vertical Batch
3 2 1 3 2 1 3 2 1

Horizontal Batch
1

1 2

2 3

- 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 8By operator, discrete input or shared data
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- Control recipes can be executed:

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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.

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IND780batch
Example Batch History Report

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IND780batch
Example Batch Details Report

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IND780batch
Example Master Recipe Details Report

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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
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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

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Internal usage only

IND780batch- Marketing Launch Materials

IND780batch Launch Letter

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/BUSI/PLM/780batch/Shared%20Documents/Forms/AllItems.aspx ftp://ftp.usa.mt.com/pub/indmkg/IND780_Batch/Index.htm
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