PAT (Process Analytical Technology) And Batch Recipe Execution

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By: Emerson Process Management

Process Analytical Technology (PAT) provides the ability for real-time, online quality control during batch recipe execution. To achieve this benefit, manufacturers must incorporate a PAT solution into their existing batch framework while leveraging existing assets and minimizing risk to existing recipes.

Emerson Process Management can assist you with implementing a PAT solution that will give you a better view of your process – the ability to predict when your quality attributes are out of specification – and when and what action is needed to avoid product quality issues.

Emerson's solution for incorporating PAT into batch recipe development and execution is composed of the following components:

• the Emerson Data Analytics modeling tool
• the Optimal synTQ® PAT data management package, and
• a recipe configured in the DeltaV™ digital automation system or in Syncade™ Smart Operations Management Suite.

The first step in implementing a PAT solution is detemining the Critical Quality Attributes (CQAs) and developing a process model.

The next step is incorporating the CQAs and process model into a PAT solution. Figure 1 illustrates how Emerson's integrated PAT architecture allows for the incorporation of batch-context-sensitive data from machinery or equipment, instrumentation, process control systems, online analyzers, and laboratory data into the models used to predict Critical Control Parameters (CCPs) or CQAs. The models may be run as part of a Syncade or DeltaV recipe or run as part of a standalone synTQ installation.

One important advantage of this architecture is that it allows the user to develop the PAT system in a "step-by-step" manner, starting with a simple PAT measurement system and then incorporating a more sophisticated approach that utilizes the Syncade or DeltaV system. This ground-up approach is central to the effective development of PAT systems because it minimizes the up-front cost and complexity of the system, but allows for an expanded scope for its future development.

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