For batch-based processes, the “golden batch” is term often used to describe the ideal batch against which all other batches are compared. In a Control magazine article, Data Analytics in Batch Operations, it is defined:
In a 2:12 YouTube video, Repeating the “golden batch”, Emerson’s Tom O’Banion, describes the need to verify accuracy with every batch made, especially in fine and specialty chemicals. He explains how online, on-demand diagnostics assure repeatability and build measurement confidence.
…as the time-based profile of the measurement values that were recorded for a particular batch that met product quality targets. When using this standard, a batch is judge by how closely the golden batch profile is maintained through the adjustment of process inputs.
He opens further describing the golden batch as being when the recipe, ingredients, the proportions and all the automation equipment are working in perfect sync, and just the right amount of each component are added. The goal of this is in later weeks or months, when that same batch needs to be run, all of the equipment settings are understood and can be reproduced to match the ideal setup.
Tom describes the concept of process genealogy in a product such as a drug or medicine in order to protect consumer safety. Having a complete history of all the components that went into the product, their purity, their amount, who the supplier was, and how much had been added into the batch process.
Flow measurement is typically one of the critical measurements for this genealogy and accuracy is paramount. Using the Micro Motion Smart Meter Verification, the accuracy of these flow measurements can be verified between batches while the meter is still inline.
Tom notes how this improves overall batch cycle time to reduce production and approval times—increasing overall performance.
You can connect and interact with other flow measurement experts in the Flow group in the Emerson Exchange 365 community.