CONTINUOUS PROCESSES C
ontinuous manufacturing is a production method that sees ingredients being continuously fed through a process and
transformed into finished products without interruption. Instead of producing items in batch or discrete runs, the system is able to operate automatically for extended periods, maintaining a steady state of production. Of course, this approach relies heavily on
the use of automation, process control, and real-time monitoring to keep operations stable and efficient. The technology is optimised for products with steady, predictable demand and, by running uninterrupted, it is able to maximise throughput and minimise losses associated with startups and shutdowns, to outperform batch manufacturing at scale. “Continuous processes operate in a steady
per-unit co s,” she sa s.
state, which can result in highly consistent operating conditions. With proper monitoring and control, this supports uniform product characteristics over time,” explains Michelle Rosinski, Senior Product Marketing Manager at GE Vernova’s Proficy Software & Services. “In practice, this level of visibility and control is typically achieved through the use of industrial software that connects process data, analytics, and operator workflows in real time.” Unlike batch manufacturing, continuous production avoids the need for frequent stoppages for changeovers which can result in higher asset utilisation and smoother operation in applications where product variation is limited. Michelle warned that continuous manufacturing is most cost- effective at scale. “For small production volumes, operating continuously can increase per-unit costs,” she says.
p operating c
IT IS IMPORTANT TO NOTE THAT, WITHOUT
PROPER MONITORING OF
CONTINUOUS PROCESSES, SMALL PROCESS DRIFTS CAN ACCUMULATE OVER LONG PRODUCTION RUNS
Continuous manufacturing is not such a
good solution in production environments where frequent product or formulation changes are needed. This is because any adjustments to a continuous process will require careful coordination and so can disrupt steady-state operation. So, for high- mix environments, batch manufacturing is often still a better fit. “It is important to note that, without
requir volume, and demand s ability
proper monitoring of continuous processes, small process drifts can accumulate over long production runs,” continues Michelle. “This makes strong process control and analytics essential.” Summing up, Michelle believes that the choice between batch and continuous manufacturing will depend on a variety of different factors, including regulatory requirements,, product variability, productionproduction volume, and demand stability.
g g product variabilit y
Important considerations When specifying a new continuous processing line Jarrod Hunt, Managing Director at Continuous Process Solutions, believes that the most important considerations relate to product limitations and specifications. “It is important to consider viscosity and stickiness, for example, as well as the product finish requirements – such as thickness and temperature. It is also important to bear in mind the space available and accessibility, and of course, it is vital to take customer expectations into account,” he says. In the short term, Jarrod pointed out that
new continuous processing lines often require a heavy investment but are a more cost-effective solution in the long term due to their lower operational costs, lower production overheads and reduced payroll costs. The approach is also more sustainable in the long run, as the equipment lasts longer. Continuous manufacturing processes are
able to reduce staffing costs not because they eliminate people entirely from the process, but because they change where and how labour is used across the operation. So, because a continuous production line
is designed to run with minimal interruption, once it has been set up and stabilised, the process flows automatically, removing the need for the same levels of manual intervention that batch or discrete production solutions typically demand. Continuous processes are usually built
around automated control systems that include routine monitoring and adjustment tasks, so one operator is usually able to
Image courtesy Schubert.
APRIL 2026 • KENNEDY’S CONFECTION • 73 APRIL 73
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