proCflex – S88-Based Batch Automation for Flexible Batch Processes
proCflex is proCtec’s flexible batch management solution for batch-oriented production processes with a high degree of variation and customization.
At its core is a modular process logic that allows complex workflows to be built and further developed using reusable structures rather than rigid ones.
The solution is based on ISA S88 and supports the modeling of units, phases, transfers, and production instructions.
This allows batch processes to be clearly organized, graphically structured, and adapted to changing requirements.
- proCflex structures batch processes using units, phases, transfers, and production instructions in accordance with ISA S88.
- The batch management system is particularly well-suited for variable manufacturing processes that undergo frequent changes or expansions.
- Reusable process building blocks support the flexible modeling and adaptation of complex batch sequences.
- Interfaces to ERP and laboratory/LIMS systems facilitate integration into existing production environments.
For which industries is proCflex suitable?
• Chemical industry
• Pharmaceutical industry
• Food industry
• Plastics and rubber industry
Typical application environments:
• proCflex is suitable for mixing plants with batch-oriented and variable production processes.
• The solution supports weighing and dosing systems in batch processes with structured recipe and material references.
• proCflex was developed for batch processes that must be flexibly modeled and traceably documented.
• The batch management system supports raw material handling in production environments with batch-based material tracking
• Transfer processes can be structured in proCflex using phase and transfer concepts.
• proCflex supports filling processes that are integrated into batch-oriented and documentation-intensive production workflows..
Flexible Process Logic Based on ISA-S88
A key feature of proCflex is its batch logic based on ISA-S88. Processes are not treated merely as a rigid sequence, but are organized into clearly defined, combinable structures.
These include:
- Units as functional plant areas
- Phases as basic operations
- Transfers as links between material and process transitions
- Production instructions (FeVo) as structured sequence definitions
This results in clearly defined, combinable process building blocks. These can be reused and specifically adapted for different products, orders, or plant configurations.
This structure offers a practical advantage, particularly in production environments with frequent changes: process logic does not have to be rebuilt from scratch each time but can be further developed and recombined within a modular architecture.
proCflex structures batch processes using units, phases, transfers, and manufacturing instructions in accordance with ISA S88.
Flexibly Modeling Production Instructions
With proCflex, production instructions (FeVo) can be flexibly structured and used in batch mode. They form the basis for step sequences and structured batch processes.
Function blocks can be freely defined and arranged within the process logic. This makes proCflex particularly well-suited for manufacturing processes where process sequences do not remain permanently the same but are adapted depending on the product, order, or line.
Additional Benefits of proCflex
Managing Formulas, Orders, and Materials in a Batch Context
Even in flexible production environments, a robust foundation for formulas, orders, and materials is essential.
proCflex supports the structured management of this information within the batch process.
Recipes can be used in the production context, orders can be integrated into the batch process, and materials can be assigned on a phase- or batch-specific basis.
In this way, proCflex combines flexibility in process logic with transparency in operational execution.
Among other things, the system supports:
- Recipe managementRezepturmanagement
- Order management
- Material Management
- Material-Tracking
- Batch Traceability
- Batch Documentation
Batch Traceability and Batch Documentation
proCflex supports the structured collection of relevant batch, material, and process data.
This creates a traceable foundation for batch documentation, material tracking, and transparency across individual process steps.
Transparency is particularly important in adaptable production environments: As processes become more variable, the need to clearly track changes, statuses, and material usage also increases.
proCflex supports batch traceability in variable batch processes.
Material tracking and batch documentation provide transparency into batch-related processes.
Three Operating Modes for Flexible Interventions and Automated Processes
- In service mode, individual actuators in proCflex can be selectively controlled via the visualization interface.
- Semi-automatic mode in proCflex allows for the targeted execution of individual phases within the batch process.
- In automatic mode, proCflex automatically executes production recipes and step sequences within the system.
- This structure supports both targeted interventions in individual process steps and the automated operation of complex batch sequences. Multiple production recipes can be processed in parallel within the system.
Visualization and Operation During Ongoing Batch Operation
proCflex provides functions for operation and monitoring within a central visualization interface. Plant statuses, phases, orders, material withdrawals, and production instructions can be displayed transparently and tracked during ongoing operation.
Elements such as the dispatcher, phase screens, or job-specific overviews help maintain a clear view of variable batch processes.
This ensures that, even with complex or customized workflows, the current status and active steps remain visible.
Integration into ERP, Laboratory, and Existing Production Environments
proCflex is designed for integration into existing production and IT landscapes. Interfaces to ERP and laboratory/LIMS environments support the structured use of recipe, order, and production data across system boundaries.
The solution can serve as a connecting layer between the field level, PLC, visualization, database, and higher-level applications.
proCflex supports integration with ERP, laboratory/LIMS, and existing production environments.
When is proCflex the right solution?
proCflex is particularly well-suited when batch-oriented manufacturing processes need to be adjusted on a regular basis.
- proCflex is suitable for products with a wide variety of variants, regularly adjusted batch processes, and changing production requirements.
- The batch management system supports frequently changing process sequences in batch-oriented manufacturing processes.
- New recipes and modified product requirements can be integrated into existing batch workflows in a structured manner within proCflex.
- proCflex supports modularly expanded line concepts and recurring adjustments to individual process steps in flexible production environments.
- While traditional batch structures are often geared toward more rigid workflows, proCflex supports the flexible modeling and combination of individual program and process modules.
The Key Benefits of proCflex at a Glance
This creates a solid foundation for standardizing production workflows, allocating resources strategically, and sustainably improving process reliability.
- proCflex structures batch processes using S88-oriented batch logic with units, phases, transfers, and manufacturing instructions.
- Reusable process modules support variable production workflows with frequent changes, expansions, or new product requirements.
- The batch management system combines flexible process logic with the structured management of recipes, orders, and materials.
- proCflex supports batch traceability, batch documentation, and transparent material sourcing throughout the entire process.
- Interfaces to ERP, laboratory/LIMS, and existing production environments support integration into existing system landscapes.
This is how a proCflex project typically proceeds
To ensure that proCflex quickly becomes effective in batch-based production, proCtec relies on a structured approach from requirements analysis through ongoing operation.
This allows batch management, automation, recipe management, and system integration to be precisely tailored to your processes.
Why proCtec?
proCflex is a solution from proCtec GmbH that builds on many years of experience in batch automation.
proCtec has been implementing batch systems since 1992 and has been carrying out projects in accordance with the S88 batch standard since 2011.
We support projects from conception through engineering and integration to commissioning and ongoing support.
This results in a solution that not only works technically but is also designed for long-term adaptability and stable process control.
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FAQ
proCflex is particularly well-suited for batch processes that need to be regularly adjusted, expanded, or recombined. This is especially relevant in production environments with a wide variety of product variants.
