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Batch production

Batch production is a manufacturing technique in which a discrete quantity of identical or similar products is produced in a group, or batch, through a predefined sequence of steps or recipe, often involving multiple workstations or vessels, before the equipment is reconfigured or cleaned for the next batch.^[1] This method contrasts with continuous production by operating in a stop-and-go manner, allowing for flexibility in producing varied items on the same machinery.^[2]^[3] Commonly applied in industries such as pharmaceuticals, specialty chemicals, food processing, and electronics, batch production enables the creation of smaller production runs tailored to demand, reducing the need for large inventories and facilitating quicker adjustments to quality specifications or market changes.^[1] Key advantages include lower initial equipment investment compared to mass production setups, the ability to produce multiple product types on shared facilities, and enhanced quality assurance through individual batch testing and repetition that supports process improvements.^[3]^[1] For instance, in pharmaceutical manufacturing, batches of active ingredients—such as 250 kg per run—can be scaled to meet annual needs like 7,300 kg through multiple cycles, often taking weeks to complete.^[3] Despite these benefits, batch production presents challenges, including higher operational costs due to downtime for cleaning and setup between batches, potential inconsistencies if disturbances affect individual runs, and complexities in scheduling that arise from its nonlinear, time-varying dynamics.^[2]^[1] In comparison to continuous manufacturing, it requires larger material volumes and equipment scales, leading to less efficiency and agility, with estimated annual costs up to 30% higher in sectors like pharmaceuticals.^[2] These drawbacks have prompted ongoing industry efforts to integrate batch methods with advanced controls, such as run-to-run optimization, to improve reliability and output uniformity.^[1]

Fundamentals

Definition

Batch production is a manufacturing technique in which identical or similar products are produced in discrete groups, known as batches, of a predetermined quantity, after which production pauses to reconfigure machinery and processes for the next batch. This method allows for the efficient handling of multiple units through shared production stages, enabling economies of scale within each group while accommodating variety across batches. According to the American Production and Inventory Control Society (APICS), batch production is defined as "a form of manufacturing in which the job passes through the functional departments in lots or batches."^[4] At its core, batch production involves sequential processing where an entire batch progresses through a series of operations—such as machining, assembly, or finishing—as a cohesive unit, rather than in a continuous stream. This non-continuous flow facilitates control over quality and inventory at each stage, using general-purpose equipment that can be adjusted between batches. The approach is particularly suited to industries requiring moderate volumes and some product customization, where the batch acts like a single entity moving through the production system.^[5] Unlike mass production, which relies on fixed, high-volume runs with dedicated lines, batch sizes in this method are highly variable, often ranging from dozens to thousands of units, depending on market demand, setup costs, and equipment capabilities. This flexibility allows manufacturers to respond to fluctuating orders without overcommitting resources to a single product type.^[5]

Key Characteristics

Batch production offers significant flexibility in product variety, enabling manufacturers to produce different items or variants by retooling machines and adjusting processes after completing one batch and before starting the next.^[6] This adaptability stems from the system's design, which supports variable batch sizes and equipment assignments, allowing for multipurpose use of machinery in environments requiring diverse outputs without dedicated lines for each product.^[6] Such flexibility makes it ideal for responding to fluctuating demands or customizing products to specific customer needs, as production can shift between types like baked goods, pharmaceuticals, or apparel components. A defining operational feature is the presence of setup and changeover times, which introduce periods of downtime between batches for tasks such as cleaning equipment, reconfiguring tools, or switching materials to prevent cross-contamination or errors.^[6] These changeovers can be sequence-dependent, varying based on the products involved, and often require careful planning to minimize production interruptions.^[6] While this intermittent nature distinguishes batch production from continuous flows, it necessitates efficient scheduling to balance throughput with preparation needs. In terms of inventory management, batch production creates intermediate stockpiles of work-in-progress (WIP) items as products move through sequential stages, leading to elevated holding costs compared to one-piece or continuous methods. However, this approach supports customization by allowing stockpiles to be allocated for varied downstream processes or modifications.^[6] Storage policies, such as finite intermediate storage or unlimited options, further influence WIP levels, enabling control over material flow but requiring robust tracking to avoid excess accumulation.^[6] Batch production operates effectively at medium-volume scales, typically ranging from hundreds to thousands of units per run, where the economies of full automation are not yet viable but repetitive efficiency is beneficial.^[7] This scale suits industries like electronics assembly or chemical processing, balancing variety and volume without the high capital demands of mass systems.^[8] Quality control in batch production benefits from the ability to isolate individual batches for targeted testing and inspection, limiting the propagation of defects to only the affected group rather than an entire production line.^[9] This isolation facilitates detailed analysis, such as using probabilistic models to assess good-part yields per batch, enhancing overall reliability through reprocessing or rejection of substandard units without broader impact.^[9]

Historical Development

Origins

Batch production has its roots in pre-industrial artisanal practices, where craftsmen produced goods in small groups to meet variable or seasonal demands, allowing for flexibility in limited-resource environments.^[10] In 18th-century workshops, this manifested in activities like baking, where loaves were prepared and fired in oven batches to serve local communities, and in brewing, involving discrete mashing and fermentation cycles of malt with hot water to yield finite quantities of ale.^[11] Similarly, pottery making relied on batch kilns to fire multiple vessels at once, adapting to material availability and market needs without continuous output.^[12] During the late 18th to early 19th-century Industrial Revolution, batch methods transitioned into mechanized manufacturing, particularly in textile mills and metalworking, enabling limited runs of standardized items via steam-powered equipment. In British textile factories around 1800, such as those employing early spinning machines, cloth was produced in batches to accommodate varying colors, patterns, and orders, contrasting with prior cottage-scale efforts.^[13] Metalworking adopted similar approaches, with crucible steel processes yielding small batches of tools and components through controlled melting and casting, limited by furnace capacities before larger-scale innovations.^[14] These developments were driven by the imperative for efficiency in markets with fluctuating demand, allowing producers to group similar tasks without committing to uninterrupted flows, thus predating assembly-line continuity.^[15] The shift from one-off crafting to batched production marked a key transition, as mechanization facilitated grouped processing of materials like wool or iron in factories, balancing customization with emerging scale.^[16]

Modern Evolution

Following World War II, batch production saw significant integration with early automation technologies during the 1950s and 1960s, particularly in process industries like chemicals and pharmaceuticals, where pneumatic controls and relay logic systems began automating sequential operations to improve consistency and reduce manual intervention.^[17] In the pharmaceutical sector, this era coincided with the establishment of regulatory frameworks, such as the U.S. Food and Drug Administration's (FDA) first Good Manufacturing Practices (GMP) regulations in 1963, which mandated standardized batch production and control records to ensure traceability and quality compliance, leading to the widespread adoption of documented batch records by the late 1960s.^[18] By the 1970s, the introduction of digital computers for direct process control further enhanced batch operations, enabling real-time adjustments in industries requiring precise sequencing, though initial applications focused more on data logging than full automation.^[19] The digital revolution from the 1980s onward transformed batch production through the adoption of computer-aided manufacturing (CAM) systems, which optimized tool paths and machining sequences to minimize changeover times between batches in discrete manufacturing environments.^[20] Concurrently, enterprise resource planning (ERP) systems, evolving from manufacturing resource planning (MRP II) frameworks in the 1980s, integrated production scheduling with inventory management to forecast demand and reduce setup durations, allowing manufacturers to handle variable batch sizes more efficiently.^[21] In the 1990s, lean manufacturing principles, popularized in Western industries after their origins in Japanese just-in-time (JIT) systems, influenced batch production by advocating smaller lot sizes to cut inventory waste and shorten lead times, fostering a shift toward more responsive production models without sacrificing economies of scale.^[22] Entering the 21st century, batch production has aligned with Industry 4.0 paradigms, incorporating Internet of Things (IoT) sensors and artificial intelligence (AI) for real-time monitoring and predictive analytics, enabling dynamic adjustments to process parameters and reducing downtime in complex batch sequences.^[23] This evolution supports flexible manufacturing systems (FMS) in sectors like electronics, where 2020s implementations use modular robotics and cyber-physical systems to accommodate rapid product variations and short runs, responding to globalization's demands for diverse, customized outputs.^[24] A pivotal milestone has been the progression to "batch-of-one" production via advanced robotics, particularly evident in automotive suppliers since the 2010s, where collaborative robots and AI-driven reconfiguration allow individualized assembly without extensive retooling, bridging mass production efficiency with personalization.^[25]

Comparisons with Other Methods

Versus Job Production

Job production involves the creation of unique, one-off items tailored to specific customer specifications, often requiring skilled labor and general-purpose equipment to handle non-standardized processes.^[26]^[27] In contrast, batch production manufactures groups of similar items in limited quantities, processing an entire batch through one stage before advancing to the next, which introduces a level of standardization while allowing for some variation between batches.^[28]^[26] The primary differences lie in customization and volume: job production excels in high customization for bespoke orders, producing low volumes (often a single unit) with no repetition, whereas batch production handles medium volumes of identical or near-identical items, enabling partial standardization and economies from repeating processes within each batch.^[27]^[28] This repetition in batch production reduces setup times and material waste compared to job production's frequent reconfigurations, leading to lower per-unit costs and greater efficiency for moderate output levels, though job production's labor-intensive approach suits highly unique demands without the need for batch scheduling.^[26]^[27] Regarding suitability, job production is ideal for prototypes, luxury custom goods, or one-off projects like tailored clothing or specialized machinery repairs, where individual attention justifies higher costs and longer lead times.^[28]^[26] Batch production, however, fits repeatable variants such as seasonal clothing lines, bakery goods in flavors, or electronic components in model series, balancing flexibility with cost savings through grouped processing without the full bespoke nature of job methods.^[27]^[28]

Versus Mass Production

Mass production involves the high-volume, continuous manufacturing of identical products through dedicated assembly lines, enabling efficient, uninterrupted output of standardized items. A seminal example is Henry Ford's implementation of the moving assembly line at his Highland Park plant in 1913 for the Model T automobile, which reduced assembly time from over 12 hours to about 93 minutes per vehicle and lowered the price from $850 in 1908 to $490 by 1914, making it accessible to the middle class.^[29]^[30] In comparison, batch production differs fundamentally by producing limited quantities of a specific product in discrete groups before reconfiguring equipment for the next variant, necessitating frequent changeovers that introduce versatility but elevate setup costs due to downtime and reconfiguration efforts. Mass production, conversely, minimizes such interruptions by dedicating machinery to a single product type over extended periods, optimizing for uniformity and reducing per-unit variability. This setup in batch production supports greater product diversity, while mass production prioritizes scale for identical outputs. Economically, batch production aligns with markets featuring fluctuating demand and varied product lines, allowing manufacturers to adjust schedules and minimize excess inventory for non-standard items, though it results in higher overall costs per unit from those changeovers. Mass production thrives in stable, large-scale environments where economies of scale drive down costs—but lacks the adaptability for rapid shifts in customer preferences. Historically, many mass production systems originated from batch-oriented methods during the early industrial era, evolving through specialization to handle volume, yet batch production preserves its core strength in flexibility for goods that defy full standardization.^[31]

Versus Continuous Production

Continuous production refers to a manufacturing method characterized by non-stop, 24/7 operations designed for processing fluids, gases, or bulk materials in a steady flow, as seen in oil refineries where crude oil is continuously distilled into fractions like gasoline and diesel without interruption. This approach relies on automated systems that maintain constant input and output rates, minimizing downtime and optimizing throughput for high-volume commodities. In chemical plants, for instance, continuous production facilitates the ongoing synthesis of products like ethylene from petrochemical feedstocks, ensuring uniform quality through fixed process parameters.^[32] Batch production, by contrast, operates in discrete cycles where a limited quantity of identical items is produced in a single run, involving clear start and stop points that allow for reconfiguration between batches.^[33] This intermittency enables flexibility in switching product types or formulations, such as adjusting mixing ratios in pharmaceutical compounding, whereas continuous production runs indefinitely with steady-state conditions that preclude easy recipe alterations without halting the entire line.^[34] The key distinction lies in flow dynamics: batch processes handle grouped units that progress together through stages, often pausing for cleaning or setup, while continuous processes feature seamless material movement from raw inputs to finished outputs.^[32] Operationally, batch production accommodates variability in product specifications by permitting equipment reconfiguration and quality checks per batch, making it suitable for diverse or customized outputs in moderate volumes.^[33] Continuous production, however, prioritizes maximum throughput via specialized, fixed-process lines that demand consistent raw materials and incur high costs from any interruptions, thus favoring standardized, high-demand items.^[34] For example, in food processing, batch methods allow for flavor variations in sauces with periodic vessel cleanings, in opposition to the uninterrupted extrusion of uniform plastic pellets in continuous polymer manufacturing.^[32] Regarding scalability, batch production excels for discrete goods produced in varied quantities, such as electronics components in lots of hundreds to thousands, where flexibility outweighs the need for constant operation.^[33] Continuous production scales best for bulk commodities where downtime is prohibitively expensive, enabling facilities to handle millions of units annually, as in steel rolling mills that operate ceaselessly to meet market demands. This contrast highlights batch's adaptability to fluctuating orders versus continuous's efficiency in stable, large-scale environments.^[34]

Implementation and Process

Operational Steps

Batch production involves a structured sequence of operational steps that ensure the production of a discrete group of identical items, maintaining uniformity throughout the process. The workflow follows a linear progression without branching, where the entire batch advances as a unit from one stage to the next, preserving batch integrity to avoid mixing with subsequent productions.^[35] This structure is defined by the ISA-88 standard (also known as IEC 61512), which provides a framework for batch control in process industries.^[36] In the planning phase, operators determine the batch size by evaluating demand forecasts, available raw materials, and production capacity constraints, often using recipe management systems to define material quantities and process parameters. This step includes production scheduling, which may span weeks or months for long-term planning and adjust dynamically on hourly or shift bases to optimize resource allocation.^[37]^[35] Preparation follows, encompassing the setup of machinery, loading of specified materials, and calibration according to the batch's recipe or design specifications, such as adapting general recipes to site-specific conditions like material sourcing or equipment compatibility. This phase refines the master recipe to link procedural elements with available units, ensuring readiness for execution while minimizing downtime during changeovers between batches.^[37]^[38] During execution, the complete batch undergoes processing through sequential stages—such as mixing, forming, and finishing—as a cohesive unit, with continuous monitoring to uphold consistency in quality and output parameters like temperature or duration. Procedural control hierarchies, as outlined in ISA-88, guide this flow, breaking it into unit procedures, operations, and basic phases executed on designated equipment modules.^[35]^[37] Completion and transition conclude the cycle with quality inspections to verify batch standards, followed by packaging of the finished products and cleanup or changeover preparations for the next batch, including state transitions like aborting or holding if issues arise. Electronic records document the entire process for traceability, enabling efficient handover while adhering to batch-specific control recipes.^[38]^[37]

Equipment and Setup

Batch production relies on versatile, multi-purpose equipment that can be reconfigured for different product runs, enabling flexibility in manufacturing varied items in limited quantities. In mechanical manufacturing, computer numerical control (CNC) mills serve as core equipment, featuring large work envelopes and high-speed spindles to process multiple parts per cycle, such as the DATRON M8Cube with dimensions of 1,020 x 830 x 245 mm and up to 60,000 RPM for efficient batch milling of prototypes or small series.^[39] In chemical and pharmaceutical industries, batch reactors are essential, typically consisting of stirred tanks with impellers, baffles, and heating/cooling jackets to maintain uniform reaction conditions during finite processing times. These reactors, often made of glass-lined steel for corrosion resistance, handle small-scale production under 1,000,000 lb/year and support multiple product grades on the same unit. Mixers, such as rotary batch mixers, complement reactors by blending dry or liquid materials uniformly in 1-3 minutes, with total discharge designs to minimize residue carryover.^[40] Facility layouts in batch production adopt a process-oriented arrangement, grouping similar workstations to facilitate material flow through sequential operations without a fixed assembly line. Workstations are organized by function—such as milling, assembly, or packaging—allowing batches to move between relevant areas, as seen in custom machinery plants where raw materials progress from receiving and storage to specialized zones like grinding or fabrication. Dedicated storage areas for raw materials and finished goods are integrated near entry and exit points to support just-in-time batch handling, while changeover zones accommodate reconfiguration between runs. This grouped setup contrasts with linear flows, promoting adaptability for diverse products but requiring clear pathways to avoid bottlenecks. Setup requirements emphasize tools and features that minimize downtime during batch transitions. Tooling kits, including shadow boards and pre-staged components, enable quick swaps via standardized procedures like Single-Minute Exchange of Die (SMED), reducing internal setup tasks when machines are stopped. Calibration tools, such as digital gauges integrated with standard operating procedures (SOPs), ensure equipment precision before each run, with real-time metrics verifying alignment to standards. Safety features, including lockout/tagout systems and automated alerts, protect workers during interruptions, complying with occupational regulations to prevent hazards from partial setups. Scalability in batch production is achieved through modular designs that allow expansion from small workshops to mid-sized facilities without full redesigns. Equipment like CNC mills supports this via automation add-ons, such as pallet changers, enabling unattended operation for growing batch sizes from prototypes to hundreds of units. Software integration, including manufacturing execution systems (MES) like BatchMaster, provides batch tracking, inventory management, and ERP connectivity to monitor production in real-time, facilitating seamless scaling across operations.^[41] Maintenance protocols focus on regular cleaning to prevent cross-contamination between batches, a critical requirement in multi-product environments. Validated cleaning procedures, outlined in SOPs, involve manual or clean-in-place (CIP) methods using detergents and rinses, with sampling to confirm residue levels below thresholds like 10 ppm or 1/1000 of the therapeutic dose.^[42] In chemical batch reactors, post-run sterilization and disassembly address microbial risks, while mechanical equipment undergoes daily inspections and lubrication to sustain reconfiguration efficiency. These practices, including documentation of cleaning efficacy, ensure compliance and operational reliability.

Benefits and Limitations

Advantages

Batch production offers cost efficiency particularly for medium production volumes, where economies of scale are realized within discrete batches, leading to lower per-unit costs than in job production without necessitating the substantial initial capital investments associated with mass production setups.^[43] This approach leverages shared setup and processing efficiencies across batch quantities, making it economically viable for scenarios where demand does not justify continuous high-volume operations.^[44] A primary benefit is its product flexibility, which enables manufacturers to adapt swiftly to market changes or introduce product varieties using multi-purpose equipment, thereby supporting customer-driven demands without the rigidity of dedicated production lines.^[43] In comparison to mass production, this flexibility allows for easier shifts between product types, enhancing responsiveness in dynamic markets.^[45] Batch production also provides quality isolation, confining potential defects or contamination to a single batch and permitting targeted recalls or corrective actions that limit broader impacts on inventory or operations.^[46] This traceability through batch records supports precise quality improvements, as issues can be isolated and addressed without disrupting subsequent production runs.^[47] Furthermore, it promotes efficient resource utilization by employing general-purpose machinery that minimizes idle time through versatile scheduling, while accommodating skilled labor across diverse tasks within and between batches.^[45] This balanced approach optimizes equipment and personnel deployment, reducing overall downtime compared to more specialized production methods. In terms of inventory management, batch production allows for strategic stockpiling of finished goods to buffer against demand peaks, thereby mitigating stockouts and enabling smoother supply chain operations through planned material and labor allocation.^[44] Buffer areas inherent in the process further aid in handling production unevenness, supporting reliable fulfillment during variable market conditions.^[43]

Disadvantages

Batch production incurs high setup and changeover costs, as retooling equipment, preparing documentation, and conducting quality checks for each new batch demand substantial time and labor, thereby extending overall cycle times and elevating operational expenses.^[48] These costs encompass wages for workers, machine adjustments, and sample production, which become more pronounced with frequent batch switches compared to continuous processes.^[48] A key limitation is the accumulation of work-in-progress (WIP) inventory, where materials and partially completed goods pile up between production stages, tying up significant capital and occupying valuable storage space.^[48] Larger batches exacerbate this issue by increasing holding costs and the potential for obsolescence, particularly in dynamic markets where demand fluctuations or technological advancements can render stockpiled items outdated.^[48] For very high production volumes, batch production proves less efficient than continuous or mass methods, as the intermittent nature of operations—marked by downtime for changeovers—hinders steady output and reduces overall profitability at scale.^[49] Continuous processes, by contrast, leverage economies of scale more effectively for large capacities, making batch approaches suboptimal for sustained, high-volume demands.^[49] Quality variability poses another challenge, with potential inconsistencies arising across batches due to variations in raw materials or rushed changeovers that disrupt process stability.^[50] In sectors like pharmaceuticals, this batch-to-batch inconsistency stems from natural fluctuations in inputs and manufacturing procedures, necessitating rigorous controls to maintain uniformity.^[50] Scalability remains difficult in batch production, as expanding output quickly demands proportional rises in operational complexity, such as additional equipment reconfiguration or expanded inventory management, without the seamless flow of dedicated high-volume systems.^[49] This can limit rapid response to surging demand, amplifying costs and delays in growth scenarios.^[48]

Applications

Industries

Batch production is widely employed across various industries where flexibility in production volumes, quality control, and adaptability to varying product specifications are essential. Key sectors include pharmaceuticals, food and beverage, apparel and textiles, electronics, and chemicals, each leveraging batch methods to address unique operational demands such as regulatory oversight, product shelf life, and market-driven customization. In the pharmaceutical industry, batch production facilitates the formulation of drugs in discrete, traceable units to meet stringent regulatory standards. The U.S. Food and Drug Administration (FDA) mandates the preparation of batch production and control records for each batch of drug product, including complete documentation of production and process control to ensure uniformity and integrity. This approach supports FDA batch numbering systems, which enable precise tracking from raw materials to finished products, critical for compliance with current good manufacturing practices (cGMP) and post-market surveillance.^[51]^[52] The food and beverage sector utilizes batch production for items like baked goods, confectionery, and brewed beverages, where recipes must be adjusted for different product lines while maintaining consistency. This method allows for the processing of defined quantities of ingredients in sequence, ensuring quality and safety amid perishability concerns, as batches can be tested and released based on shelf-life requirements. Regulatory compliance drives its adoption, with FDA guidelines requiring batch records for dietary supplements and similar products to document manufacturing steps and verify adherence to hazard analysis and critical control points (HACCP). Perishability further necessitates batches to minimize waste and align production with demand fluctuations in seasonal or perishable goods.^[53]^[54] In apparel and textiles, batch production supports seasonal clothing runs and dye batches, enabling manufacturers to produce limited quantities tailored to fashion trends or color variations. This is particularly suited to the industry's demand uncertainty tied to seasonality and style changes, allowing efficient use of shared equipment for diverse product lines without continuous reconfiguration. Customization is a key driver, as batches facilitate small-scale runs for varied designs, reducing overproduction in a market influenced by rapid trend cycles.^[55] Electronics manufacturing relies on batch production for assembling components such as circuit boards in grouped lots, accommodating variations in specifications while optimizing production runs. Printed circuit board (PCB) assembly often occurs in batches to enable quality checks between stages like soldering and testing, supporting the production of similar but not identical units for diverse applications. This method addresses customization needs in electronic materials and devices, where batch processing allows flexibility in scaling for prototypes or market-specific variants.^[56] The chemicals industry applies batch production for mixed quantities of products like paints and adhesives, where reactions occur in controlled reactor volumes to achieve precise formulations. Batch reactors are standard for liquid-phase processes requiring extended reaction times, such as pigment dispersion in paints, enabling adjustments for different viscosities or additives. Drivers include regulatory needs for traceability in hazardous materials and customization for specialized applications, with batch sizes up to 40,000 dm³ common for paints to balance efficiency and product diversity. Perishability factors into adhesive production, where batches prevent degradation during mixing.^[57]^[58]

Real-World Examples

In the bakery industry, small and medium-sized operations often employ batch production to manage daily output efficiently, such as producing loaves of bread in dedicated runs during the day before switching equipment overnight to bake pastries or other goods, allowing for flexibility in response to fluctuating demand. This approach minimizes downtime while accommodating product variety, as seen in commercial facilities where bakers handle multiple product types in sequence to meet seasonal or order-based needs.^[59]^[60]^[61] A prominent pharmaceutical example is Pfizer's production of its COVID-19 vaccine (Comirnaty), where batches were manufactured in isolated lots at facilities in multiple countries, each undergoing rigorous purity testing and quality control before distribution to ensure safety and efficacy. The process involved a 60-day cycle per batch, starting with mRNA synthesis and culminating in fill-finish operations, enabling the company to scale up from initial clinical batches to producing over 3 billion doses globally by the end of 2021.^[62]^[63]^[64] In the automotive sector, parts suppliers frequently use batch production for components like engine parts, running lots before retooling for variants to balance efficiency and customization demands from original equipment manufacturers. This method supports just-in-time delivery while allowing adjustments for different vehicle models, as demonstrated in mid-volume manufacturing runs that integrate machining and assembly in discrete batches.^[65]^[66] Craft beer microbreweries exemplify small-batch production by brewing limited quantities per run of unique flavors weekly, enabling experimentation with ingredients like hops or fruits without committing to large-scale output. This iterative process allows brewers to refine recipes based on taste tests and market feedback, fostering innovation in a competitive landscape dominated by mass-produced beers.^[67]^[68] Electronics manufacturers producing smartphone accessories, such as colored protective cases, often operate in batches to meet retailer orders, utilizing injection molding and assembly lines that can switch colors or designs between runs for variety. This scale supports cost-effective customization while maintaining inventory for diverse device models, as common in wholesale supply chains for mobile accessories.^[69]^[70] Batch production's flexibility proved crucial during the COVID-19 pandemic, enabling pharmaceutical firms like Pfizer to rapidly pivot from standard operations to high-volume vaccine output, accelerating global response efforts through scalable, testable lots that minimized risks and facilitated regulatory approvals. In broader terms, this adaptability in batch systems allowed manufacturers across sectors to adjust to sudden demand shifts, underscoring its role in crisis resilience.^[71]^[72]

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In a batch production process the product is made in batches or lots. Batch processing typically involves assembly-based processing using fluids and dry ...
[37]
[PDF] BATCH PROCESSING WITH S88 - Hallam-ICS
Discrete Process: A discrete manufacturing process involves the production of individual parts that move from one station to the next.
[38]
[PDF] How to Optimize Batch Cycle Production While Enhancing ...
Batch production in specialty chemicals presents unique complexities. Each manufacturing run requires precise orchestration of multiple process steps, raw.
[39]
https://www.datron.com/cnc-machines/m8-cube/
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https://www.munsonmachinery.com/Rotary-Batch-Mixers/Features.php
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https://www.batchmaster.com/
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https://www.fda.gov/inspections-compliance-enforcement-and-criminal-investigations/inspection-guides/validation-cleaning-processes-793
[43]
https://www.sciencedirect.com/science/article/pii/B9780750662772500013
[44]
(PDF) Optimization of a Product Batch Quantity
### Summary of Disadvantages/Limitations of Batch Production
[45]
Design of Batch Versus Continuous Processes: Part III - ResearchGate
Aug 7, 2025 · Merging of tasks makes the batch alternative more attractive at small production rates because economy of scale has a stronger effect on small ...
[46]
Batch-to-Batch Quality Consistency Evaluation of Botanical Drug ...
Botanical drug products have batch-to-batch quality variability due to botanical raw materials and the current manufacturing process.
[47]
21 CFR 211.188 -- Batch production and control records. - eCFR
Batch production and control records shall be prepared for each batch of drug product produced and shall include complete information relating to the ...
[48]
Q7A Good Manufacturing Practice Guidance for Active ... - FDA
Written procedures should be established and followed for the review and approval of batch production and laboratory control records, including packaging and ...
[49]
Small Entity Compliance Guide: Current Good Manufacturing ... - FDA
Yes. The DS CGMP rule requires you to prepare a batch production record every time you manufacture a batch of a dietary supplement. (21 CFR 111.255(a)).
[50]
Batch Process vs Continuous Process for Food Manufacturers | Tulip
May 20, 2025 · A batch process involves a set of ingredients and a sequence of one or more production steps that follow a pre-defined order.
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[PDF] The U.S. Textile and Apparel Industry - Princeton University
3. improved communication links, coupled with new batch production strategies, can allow re- tailers to keep a wide range of styles and sizes.
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Everything You Need to Know About PCB Batch Production
Dec 23, 2022 · PCB batch production is a process in which a large number of printed circuit boards (PCBs) are manufactured at once, rather than producing them individually.
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Batch - Visual Encyclopedia of Chemical Engineering Equipment
Apr 4, 2022 · Batch reactors are used in a wide variety of applications. Typically, they are used for liquid phase reactions that require a fairly long reaction time.
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Paints - The Essential Chemical Industry
Amounts ranging up to 40 000 dm3 of paint may be made in a single batch. ... Emulsion paints dry by a physical process involving the evaporation of water ...
[55]
Modeling and optimization of bakery production scheduling to ... - NIH
Jan 5, 2023 · This paper investigates three manufacturing lines from small and medium-sized bakeries to find optimum makespan and ovens' idle time (OIDT).
[56]
Bakers : Occupational Outlook Handbook - Bureau of Labor Statistics
Commercial bakers, also called production bakers, work in manufacturing facilities that produce breads, pastries, and other baked products. In these facilities, ...
[57]
[PDF] Alternative Control Technology Document for Bakery Oven Emissions
Production volumes, for example, fluctuate by daily orders, holidays, and seasonal fluctuations. 2.2.1. Dough Processes. Bread production at large commercial ...
[58]
How Pfizer Makes Its Covid-19 Vaccine - The New York Times
Apr 28, 2021 · It's the start of a complex manufacturing and testing process that takes 60 days and involves Pfizer facilities in three states.
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Delivering 3 billion doses of Comirnaty in 2021 | Nature Biotechnology
Feb 2, 2023 · Pfizer and BioNTech advanced Comirnaty from research to product, gaining authorization in December 2020 and manufacturing 3 billion doses by the end of 2021.
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The journey of a lifetime — development of Pfizer's COVID-19 vaccine
Sep 1, 2022 · ... produce a formulation lab, design an industrial process, and produce the first batch of BNT162b2 within an astounding 100 days. Many efforts ...
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Batch Production in Manufacturing: A Comprehensive Guide
Batch production is a method where manufacturers produce identical products in one run, with quality checks after each process step, and defined quantities.
[62]
Manufacturing at Different Magnitudes Part 2: From 100 – 1,000 Units
Oct 19, 2017 · If you're looking to produce 100-1,000 units, this is likely a batch of finished goods being sold to real customers, which could be a first ...
[63]
Crafted in Small Batches: The Art of Microbrewing
Small-batch production allows for meticulous quality control. Each batch can be sampled and refined, ensuring that the end product meets the brewer's standards.
[64]
What Is Small Batch Beer Brewing? All You Need To Know
May 16, 2024 · Small batch beer brewing allows brewers to experiment with flavors, textures, and ingredients, creating unique brews that stand out in the vast sea of mass- ...
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https://www.eworkplaceapps.com/blog/batch-production-in-manufacturing/
[66]
Bulk Custom Cell Phone Cases, Factory Price | LovingCase
LovingCase offers hybrid, 3D, tough, printed glass, and flowing sand cases. MOQ for iPhone sizes is 50 units, Samsung from 200. Bulk order lead time is 5-15 ...
[67]
Manufacturing Innovation Will Be Key to Future Pandemic Response
Feb 2, 2022 · Manufacturing innovation is key for future pandemic response, as it was central in the COVID-19 response, and can drive down response time.
[68]
Increase in vaccine manufacturing capacity and supply for COVID ...
Apr 23, 2021 · EMA has approved an increase in batch size and associated process scale up at Pfizer's vaccine manufacturing site in Puurs, Belgium.<|separator|>