Revolutionizing Batch Production: Discover How SIEMENS is Solving the Industry’s Biggest Challenges.
In today’s fast-paced manufacturing landscape, batch production facilities face mounting pressure to be more agile, transparent, and sustainable. From managing complex recipes to ensuring regulatory compliance and reducing environmental impact, the challenges are significant.
Challenge 1: Automating Recipe Control Without the Headache
Traditionally, automating batch production has required extensive custom programming—building recipe editors, batch engines, and order management systems from scratch. This not only demands high engineering effort but also results in rigid systems that are difficult to maintain and scale.
SIEMENS’ Solution:
SISTAR® provides an out-of-the-box, scalable platform that includes all essential components for batch automation. With built-in recipe editors, web-based visualization, and MES integration, these systems eliminate the need for custom development.
Key Benefits:
- Low engineering effort: Standardized tools reduce development time and complexity.
- Faster time to market: Easily adapt recipes without modifying PLC code.
- User-friendly control: Operators gain full visibility into processes, ensuring consistent product quality.
Challenge 2: Achieving Full Plant Transparency
Manufacturers must comply with strict quality regulations, which require detailed documentation and traceability. When quality issues arise, quickly identifying the root cause is essential to maintaining efficiency and avoiding costly downtime.
SIEMENS’ Solution:
With SCADA-based batch processing, SISTAR® offers comprehensive batch reporting and real-time access to historical data. Operators can track materials and products throughout the production lifecycle, ensuring full traceability and compliance.
Key Benefits:
- Standardized reporting: Gain insights into production efficiency and batch history.
- Efficient troubleshooting: Replay process data to pinpoint issues quickly.
- Seamless IT integration: Easily connect with MES and third-party systems via standardized interfaces.
Challenge 3: Reducing Environmental Impact Through Data-Driven Insights
Sustainability is no longer optional—it’s a business imperative. Yet many manufacturers struggle to correlate energy consumption with production data, making it difficult to optimize resource use and meet environmental goals.
SIEMENS’ Solution:
By integrating energy data with batch production data, SISTAR® enables manufacturers to calculate energy consumption per batch and identify inefficiencies. Integration with SIMATIC Energy Manager Pro and the TIA Portal energy library allows for cross-site comparisons and real-time monitoring.
Key Benefits:
- Energy transparency: Monitor and optimize energy use per product or batch.
- Cross-site benchmarking: Compare energy performance across facilities.
- Quick identification of energy losses: Detect and address inefficiencies in equipment and processes.
Conclusion: A Smarter, Greener Future for Batch Manufacturing
SISTAR® is transforming batch production by offering a standardized, customizable platform that simplifies automation, enhances transparency, and supports sustainability. Whether you're looking to streamline operations, ensure compliance, or reduce your environmental footprint, SIEMENS provides the tools to help you succeed—efficiently and effectively.
Click here to find out more about SISTAR® .
We are pleased to invite you to visit the SIEMENS booth at iba 2025 to learn more.
📍 Location: Hall 10, Booth H46
📅 Dates: 18 – 22 May 2025, Düsseldorf
