Challenges with performance management of automatic control loops in a large-scale batch processing environment

Process-related industries (many of which are inherently batch-related) account for a significant portion of the manufacturing sector. Many advances have been made in the field of process control, some of which are related to performance management of control loops. However, much of this work assumes continuous operation of the control loops. Many of the challenges presented by batch environments relate to a requirement to cater for both interruptions to control loops as well as varying plant dynamics. This paper provides both an overview of the general issues that are likely to be encountered in a batch environment as well as some deeper insights into a number of specific challenges. Some examples are provided based on experience within one of Australia's largest breweries. Despite this being a topic of emerging importance to manufacturing industries there is very little objective (non-commercial) information on these challenges available in the literature. This material will be of benefit to researchers who have an interest in realistic industrial control applications. It is also intended to be of use for those in industry by providing a realistic set of issues and challenges that are specific to batch environments.