Process Control Solutions & Batch Control System Integration
Precision batching. Zero surprises. Full traceability from raw material to finished product.
Concept Systems designs, integrates, and supports process control systems and batch control systems that deliver consistent, compliant, and scalable production for plant managers in food & beverage, building materials, mining, and other process-intensive industries. From single-line upgrades to plant-wide PlantPAx deployments, we turn complex recipes and regulatory requirements into reliable, repeatable automation.
How Our Process Control Integration Delivers Operational Excellence
We start with your recipes, quality specs, and compliance needs, then engineer a fully integrated solution using Rockwell PlantPAx, FactoryTalk Batch, or custom Ignition platforms. Every system is simulated, FAT-tested in our facility, and commissioned with minimal production impact—so you gain tighter process control, reduced waste, and audit-ready documentation from day one.
In industries where off-spec batches cost tens of thousands and regulators demand traceability, our process control solutions eliminate manual errors, shorten changeover times, and give operators real-time visibility across the entire plant.
Key Benefits You Gain From Our Process Control Systems
- Achieve ±0.1 % batch accuracy and full ISA-88 compliance
- Reduce batch cycle times by 20–40 % with automated sequencing
- Eliminate off-spec product and rework through precise material addition
- Shorten changeover times with recipe-driven automation
- Gain complete electronic batch records for FSMA, FDA, or NADCAP audits
- Lower energy and raw material costs with optimized control loops
- Enable remote monitoring and faster troubleshooting
- Scale seamlessly from pilot to multi-site production
What Concept Systems Delivers in Every
Process Control & Batching Project
System Design & Simulation
- Detailed Process Flow Diagrams (PFDs) and P&IDs
- Recipe development and phase logic per ISA-88 standards
- Emulate3D or FactoryTalk Batch simulation before build
- Control narrative and loop tuning strategy
Core Engineering Services
- PlantPAx distributed control system (DCS) architecture
- FactoryTalk Batch & PhaseManager programming
- Integration of weigh scales, valves, pumps, and mixers
- Advanced process control (APC) and model-predictive strategies
Hardware & Deployment
- In-house UL-508A panel fabrication
- Skid or field-mounted instrumentation integration
- Factory Acceptance Testing with water-batch or simulated runs
- Site commissioning and performance qualification (IQ/OQ)
Validation & Training
- Electronic batch record (EBR) and audit trail setup
- Operator and maintenance training on recipe management
- Full validation documentation packages (when required)
- Long-term support and annual optimization audits
Industries We Serve With Process Control & Batch Systems
- Food & Beverage (largest segment)
- Building Materials
- Mining & Metals
- Chemicals & Specialty Materials
- Water / Wastewater Treatment
Typical Process Control & Batching Applications We Integrate
- Multi-stream batch mixing and blending
- Recipe-driven food processing lines
- Dry / wet ingredient dosing and weighing
- Kiln and dryer temperature control loops
- CIP (Clean-in-Place) automation
- Silo and material transfer management
- Packaging and filling synchronization
Why Manufacturers Choose Concept Systems for Process Control Integration
With 25 years of Rockwell PlantPAx and FactoryTalk Batch deployments—including a global frozen potato processor standardized across 12+ plants—our principal engineers who literally wrote the book on batching lead every project. We own the entire lifecycle in-house (no subcontractors for panels or programming), so your system is delivered faster, validated correctly the first time, and supported for decades.
Process control
Looking to learn a little more?
Read how our process control abilities helped one food manufactures expand their production capacity and become the first frozen food processing plant in the world to earn LEED platinum certification.
Get Started With Process Control & Batch Automation
Ready for repeatable, audit-proof batches and lower operating costs?
Contact Concept Systems today for a no-obligation process assessment.
Frequently Asked Questions About Process Control & Batch Systems
Do you work with Rockwell PlantPAx?
Yes. Concept Systems has delivered PlantPAx-based process control and modernization projects for years, including system architecture, controller and HMI development, network and historian integration, and commissioning support. We also help clients standardize templates, alarms, and graphics so PlantPAx is easier to maintain and scale across lines or facilities.
What other DCS systems do you work with?
In addition to PlantPAx, we integrate and modernize a range of DCS platforms—including Emerson DeltaV and Siemens PCS 7—as well as legacy systems when that’s what your facility standard requires. Our goal is to align with your internal standards and support model, not force a platform change that creates unnecessary cost or risk.
What other DCS systems do you work with?
While PlantPAx is our primary platform, we are a system-agnostic integrator and work with several other systems. We integrate platforms like Ignition, Emerson DeltaV, and Siemens PCS7 when they better fit the client’s existing standards or project requirements. We also have experience upgrading and working with other legacy DCS systems.
How long does a full batch control system integration take?
Typical projects run 6–12 months from kickoff to validated production, with most panels and code developed off-site to minimize downtime.
Can you upgrade an existing manual or semi-automatic batch process?
Yes — we specialize in phased brownfield migrations that keep current production running during the upgrade.
Do you provide validation documentation for regulated industries?
Absolutely — we deliver full IQ/OQ/PQ packages and 21 CFR Part 11-compliant electronic records when required.
Is remote monitoring of batch systems included?
Yes — all new systems include secure FactoryTalk View SE or Ignition remote access with alarm notification.
What if we only need a single-line batching upgrade?
We handle projects of any size — from one new dosing station to plant-wide DCS.
Are you capable of designing and implementing Safety Instrumented Systems (SIS)?
Yes. We have decades of experience designing, validating, and implementing Safety Instrumented Systems (SIS) as part of our comprehensive process control projects. We work to industry standards to ensure the safety of your personnel and facility, including specialized safety PLC programming and documentation.