Continuous process is a manufacturing method that produces a large amount of product in a short time. It is used in the production of chemicals, drugs, glass, and refining crude oil. The system requires timely maintenance and uses a PID controller to adjust the system. The production method depends on the product, and batch production allows for testing of product quality but requires downtime.
In manufacturing, a continuous process is a method used by manufacturing or production companies to churn out the greatest amount of product in the least amount of time. This is consistent, constant, and uninterrupted, in contrast to batch processing. Manufacturers often use this type of process in the manufacture of chemicals, drugs and glass, as well as in the process of refining crude oil. A continuous process plant is designed in such a way as to ensure a continuous flow of product from one machine or robot station to another during the production process. Complex equipment and software programs that collect feedback from several stations regulate the rate of flow through the system, closely controlling the rate of production.
Timely maintenance on a continuous process system is essential. The system is set up in a serial configuration, with a dynamic progression of the product in the factory. Any failure in a machine delays the supply chain both upstream and downstream of the defective machine. Although the continuous process system is automated, human input and management keeps the process going as intended. These systems require a substantial investment in the design of systems, transducers, controllers, and complex machinery to achieve the desired goal of around-the-clock production.
Most continuous process systems use a proportional integral integral (PID) controller. A PID controller collects feedback from various control points in the system and performs three calculations. Proportional calculation detects an “error” by comparing a measured output value to a predetermined setpoint. Integral calculations average the most recent errors to evaluate trends, while derivative calculations look at the rate of change of the error. The controller uses the weighted sum of the three calculations to adjust the system by altering a control point such as the speed of a conveyor belt, the position of a valve, or the temperature of a heating element.
The production method used by a given plant depends on the product. Continuous flow production requires products for which the same level of quality can be reliably achieved as long as the manufacturing process and ingredients are unchanged. If product quality varies significantly, batch production allows you to test the quality of a limited amount of product. While batch production requires less upfront capital investment and can be adjusted according to market demand, it requires downtime between batches for reconfiguration and testing. Continuous process manufacturing reduces production costs by eliminating downtime.
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