Connect SAP Batch Management directly to multi-vessel batch PLCs. Orchestrate complex formulations, clean-in-place cycles, and real-time electronic batch records (EBR) compliant with regulatory traceability standards.
Process industries such as pharmaceuticals, biotechnology, specialty chemicals, and food processing operate under tight regulatory scrutiny. Every ingredient added, temperature ramp executed, and phase completed must be documented with ironclad traceability linking SAP batch numbers to physical equipment sensors.
Manual paper batch records (PBRs) are vulnerable to transcription errors, missing operator initials, and retrospective logging. During quality audits, compiling batch release documentation takes days of manual paper retrieval.
Batch plants must maintain multi-level genealogy (raw material lots → intermediate phases → finished batch). Disconnected PLCs cannot link individual dosing events back to SAP inspection lot numbers automatically.
Our integration software bridges SAP Batch Management with industrial PLCs adhering to ISA-88 standards. It downloads validated recipe procedures, enforces dosing interlocks, records timestamped sensor telemetry for every phase, and automatically generates audit-ready Electronic Batch Records (EBR) upon batch completion.
Industrial shop-floor implementation with sub-second PLC telemetry & automated ERP synchronization.
Our specialized application connects directly to machine controllers and enterprise systems without invasive code modifications, establishing deterministic real-time communication across industrial fieldbuses.
Transactional Buffer • RFC/BAPI Connectors • Protocol Translation (OPC UA, Profinet, Modbus, MQTT) • Store & Forward Caching
Physical Batch Telemetry → PLC Phase Registers → Batch Engine Middleware → Electronic Batch Record → SAP Batch Master
Eliminates paper batch sheets, shortens batch release quarantine from days to minutes, and provides tamper-proof regulatory compliance documentation.
Built for high-speed industrial environments where downtime is measured in seconds.
Implements standard procedural states (Idle, Running, Holding, Paused, Aborting, Completed) in coordination with PLC logic.
Supports dual-operator electronic sign-offs for critical ingredient charging and phase transitions.
Binds consumed raw material lot barcodes directly to specific reactor dosing phases and finished batch IDs.
Records high-precision temperature, pH, pressure, and dissolved oxygen trends throughout the entire batch cycle.
Enforces mandatory electronic verification that equipment was sanitized and inspected prior to batch initiation.
Generates comprehensive PDF batch release dossiers containing trends, alarms, and confirmation numbers.
Direct compatibility with leading global industrial automation and ERP ecosystems.
How data seamlessly flows from top-floor enterprise orders to shop-floor machine feedback.
The integration middleware queries SAP for approved batch process orders and assigned raw material lot IDs.
Pre-batch verification checks clean-in-place (CIP) certificates, line clearance, and calibration tags in the PLC.
Multi-phase recipe setpoints (Charge, Heat, Agitate, Hold, Cool, Discharge) are loaded into controller sequencers.
The PLC executes each phase automatically, capturing start/stop timestamps, temperatures, and dosing weights.
When the batch discharges, an electronic batch summary is compiled and synchronized directly into the SAP Batch Master.
Proven operational results across discrete and continuous processing plants.
Application: Multi-step reactor automation and EBR in Hyderabad and Vizag.
Application: Exothermic reaction temperature profile enforcement in Ankleshwar and Vapi.
Application: Automated fermentation and CIP cycle tracking integrated with SAP in Aurangabad and Pune.
Application: Liquid blending and automated packaging lot synchronization in Gujarat.
Why manual spreadsheets, point-to-point scripts, and isolated SCADA fall short.
| Evaluation Dimension | Traditional / Manual Methods | Compiled Successfully Platform | Operational Impact |
|---|---|---|---|
| Data Acquisition & Entry | Manual paper logbooks or end-of-shift spreadsheet entry | Sub-second automated PLC telemetry streaming & ERP posting | Zero transcription error; 100% real-time data integrity |
| Downtime & Alert Response | Local audible sirens in noisy shop floor; delays of 20-45 mins | Instant SMS, WhatsApp, and mobile push notifications with root-cause context | MTTR reduced by up to 50%; immediate intervention |
| Recipe & Parameter Download | Manual operator entry on HMI keypad; high risk of human error | Automated bidirectional recipe download from SAP order with 4-way handshake | Eliminates wrong recipe setups and expensive scrap batches |
| Architectural Resilience | Brittle point-to-point scripts without buffering; breaks on network drop | Industrial-grade Store-and-Forward with TLS 1.3 encryption | Zero telemetry loss even during enterprise network outages |
Engineered strictly according to international standards for industrial automation: ISA-95 enterprise-control integration, ISA-18.2 alarm management lifecycle, 21 CFR Part 11 electronic batch records, and TLS 1.3 / mTLS outbound cryptographic security. Built-in Store-and-Forward guarantees zero telemetry loss during network drops.
Connect a single production line in under 3 weeks with zero line disruption.
Request Pilot DemoTurnkey industrial automation and smart factory integration deployments across major industrial corridors in India.
Technical and operational answers for plant managers and automation engineers.
Discuss your PLC, SCADA, machine monitoring, IIoT or Industry 4.0 requirement with our industrial automation team. See how PLC events, SCADA alarms, machine downtime and industrial conditions can be monitored through web dashboards and mobile alerts.
