Managing Stopped, Aborted, and Closed Batches in SIMATIC BATCH Control Center

In SIMATIC BATCH Control Center (BATCH CC), a batch that has entered the 'Closed' or 'Aborted' state cannot be resumed, restarted, or edited under any circumstances. According to ISA-88 batch control standards and SIMATIC BATCH operational rules, terminal states permanently freeze the electronic batch record (EBR) to preserve historical data integrity. If a batch was stopped or aborted unintentionally, operators must create a new batch order referencing the desired master recipe. To prevent unarchived terminal batches from accumulating and causing database bloating in the SIMATIC BATCH database (sbdata.mdf), configure the BATCH CC Project Settings under the 'Batches' tab to enable automatic archiving and scheduled deletion of completed batches.

ISA-88 State Model and SIMATIC BATCH Lifecycle Rules

SIMATIC BATCH implements the international ANSI/ISA-88 (IEC 61512) standard for batch control architecture. Within BATCH Control Center (BATCH CC), every production order and control recipe progresses through a strictly defined finite state machine:

Created / Planned: The batch order exists in the schedule; raw material quantities and formula parameters may be modified.
Released: The batch is validated against available equipment, and recipe headers are locked.
Active / Running: Control recipe phases execute sequentially or concurrently on the target automation system (AS).
Holding / Held / Paused: Temporary transitional states where recipe execution is interrupted by operators or interlocks, but unit allocations remain reserved.
Stopped / Aborted / Closed: Terminal states where batch execution is permanently concluded.

Terminal States vs Recoverable States: Why Aborted Batches Cannot Restart

A frequent operational point of confusion arises when an operator accidentally clicks Stop or Abort in BATCH CC and subsequently attempts to restart the batch:

1. Recoverable States (Hold and Pause)

If an unexpected equipment malfunction occurs during recipe execution:
* Placing the batch in Hold (Holding -> Held) de-energizes control phases to safe states while retaining all current step indices, setpoints, and allocated equipment.
* Once the equipment issue is resolved, clicking Resume seamlessly continues recipe execution from the exact point of interruption.

2. Terminal States (Stop, Abort, Close)

Stop: The batch executes a controlled shutdown sequence, completes active phase cleanup logic, and transitions to Stopped, followed by Closed.
Abort: The batch executes an emergency immediate shutdown, overriding normal sequence logic and setting status to Aborted.
Closed: The electronic batch record (EBR) is finalized, audit trails are sealed, and unit allocations are released back to the plant pool.

By design, an Aborted or Closed batch can never be restarted. Re-executing the production run requires creating a new batch order.

Database Maintenance: Preventing BATCH Database Bloat

Every batch order in BATCH CC generates extensive time-series records, operator audit trail entries, process parameter logs, and step transition timestamps stored in the SIMATIC BATCH Microsoft SQL Server database (sbdata.mdf / sbdata.ldf).

If completed, aborted, or stopped batches are allowed to remain indefinitely in the active BATCH CC order list:
* The active database file grows rapidly, consuming gigabytes of storage.
* BATCH CC UI responsiveness degrades significantly, resulting in sluggish navigation and slow order filtering.
* Recipe compilation times and AS communication synchronization cycles lengthen.

In production environments, a rigorous archiving and deletion policy must be enforced to keep the active batch list clean while preserving full regulatory compliance.

Configuring Automated Archiving and Batch Deletion Policies

To establish proper database hygiene in SIMATIC BATCH CC:

Launch BATCH Control Center with administrative privileges.
In the menu bar, navigate to Options -> Project Settings.
Select the Batches tab:
* Archiving Policy: Configure automatic archiving upon completion (Archive batches automatically after closing).
* Target Archive: Direct archives to the Process Historian (PH) or a secure network archive path (XML/PDF formats).
* Deletion Policy: Select 'Delete batches automatically after archiving' or configure a retention threshold (e.g., delete batches older than 30 days that have confirmed archive status).
For training or testing systems where archiving is not required, manual deletion can be performed:
* Right-click the aborted/closed batch -> select Archive (or bypass via administrative override) -> click Delete.

SIMATIC BATCH State Transition and Action Reference Matrix

The following table outlines the SIMATIC BATCH state lifecycle, allowable operator transitions, and database actions:

Batch StatusState CategoryCan Be Resumed?Equipment Allocated?Permitted Operator ActionPlanned / CreatedPre-executionN/A (Not started)NoRelease, edit formula, or deleteRunningExecutionN/A (Active)YesHold, Pause, Stop, or AbortHeld / PausedInterruptedYes (via Resume)YesResume, Restart Phase, Stop, AbortStoppingTransitioningNoYesWait for phase cleanup to finishAbortedTerminalNoNo (Released)Archive and Delete; Create new batchClosedTerminalNoNo (Released)Archive and Delete; Generate batch report

Enforcing correct state management preserves batch record integrity while maintaining optimal database performance.

Verification

To verify correct batch handling and database hygiene:
1. In BATCH CC, create and release a test batch.
2. Verify that clicking Hold allows the batch to enter the Held state, and clicking Resume restores normal execution.
3. Abort the test batch; confirm that the status transitions to Aborted and that the Resume command is permanently greyed out.
4. Execute the archive command on the aborted batch; confirm that the electronic batch report is generated and transferred to the archive destination.
5. Verify that the batch can now be deleted from the active order list, maintaining a lean active database.

Limitations and Operational Precautions

In FDA 21 CFR Part 11 and GMP-regulated environments, batches must never be deleted from BATCH CC without verified, tamper-proof electronic archiving to Process Historian.
Do not perform direct SQL edits or manual record deletions on the SIMATIC BATCH database (sbdata.mdf); always use BATCH CC administrative tools.
Aborting a batch bypasses standard recipe drainage and cleaning sequences; operators must manually verify equipment status before initiating subsequent runs.
Always ensure that BATCH Server redundancy is fully synchronized before executing large batch deletion or archiving operations.

Engineer FAQ

Can a batch that was stopped accidentally be restarted from the step where it stopped?

No. The ISA-88 batch state engine considers a stopped batch terminal. You must create a new batch and, if necessary, use recipe jump/step activation features in manual mode to align the new batch with physical plant conditions.

What is the difference between Stop and Abort in SIMATIC BATCH?

Stop allows active recipe phases to execute their programmed stop logic (e.g., closing valves gracefully and stopping agitation), whereas Abort immediately de-energizes all outputs regardless of process state.

How do I clear hundreds of old batches in a test system quickly?

In BATCH CC Project Settings under the Batches tab, enable the option to allow deletion of unarchived batches, select multiple batches using Shift+Click, and execute Delete.