Continuous process optimization in terms of product yield and throughput is an ongoing activity in every batch manufacturing facility. Increasing operating costs dictated that wasteful and inefficient operating practices be eliminated. The need for optimum performance on a batch-by-batch basis drives the effort to achieve a repetitive perfect batch.

This paper presents a real-life batch distillation case for which performance was driven from a state of frequent batch failures to one that has not been seen a batch failure in over a year. In addition, the process performance has been improved to the point that average batch cycle times have been cut by 15% and first time right batch yields have been increased by 208%.

With superior process knowledge at hand, it is now time to design and implement advanced automation features that will improve batch reproducibility, further augment first pass batch yields and improve throughput.

Process analysis methodology, process data and advanced automation strategies will be presented.