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Debottlenecking

Debottlenecking by Continuous Manufacturing: Capacity Increase by 50% and Doubled Yield gave an Efficiency Boost

In the past, this customer of Microinnova had produced the same fine chemical product in four batch vessels. Microinnova developed a continuous process for fine chemical products (Batch-to-Conti). This process was scaled up to manufacturing by designing a continuous plant, using 2 of the 4 existing vessels. The redesigned plant enables an increase of the production volume by 50 % and a doubling of the yield. The manpower previously needed for production was reduced by 90 % after the plant had been automated and switched form manual operation to supervision of the automated manufacturing. 

Microinnova developed a continuous process for fine chemical products (Batch-to-Conti). This process was scaled up to manufacturing by designing a continuous plant, using 2 of the 4 existing vessels. The redesigned plant enables an increase of the production volume by 50 % and a doubling of the yield.

 

Continuous Manufacturing Case Study: Efficiency concept for Injectables boosts manufacturing efficiency and reduces quality costs

Microinnova has developed a concept for an efficiency push in a manufacturing plant for injectables of a European Pharmaceuticals Global Player. The main aim of the project was the opportunity to generate a fundamental boost in efficiency for manufacturing. Continuous formulation plants enable complete mixing within minutes instead of hours, which reduces the reactor volumes by a factor of more than 100. Additionally, this leads to an increase in quality, since the batch process did not lead to a product within specification limits on the first attempt.  The batch process was tested and corrected until the product fit the tight specification resulting in high quality costs. The continuous solution enables quality control by PAT tools. 

 Continuous formulation plants enable complete mixing within minutes instead of hours, which reduces the reactor volumes by a factor of more than 100. Additionally, this leads to an increase in quality, since the batch process did not lead to a product within specification limits on the first attempt.

 

Plant re-design for a 2-step, 3 tons per hour chemical process:

The request of a specialty chemical manufacturer was to double the production volume of a two-stage process, but the possibilities to a spatial extension were missing. This and two other problems were able to be solved with process intensification in one go!

  • Minimal intervention with maximum effect
  • Process simplified – first exothermic batch step switched to continuous
  • Production volume doubled
  • Cut-down energy costs

Investment costs were of about 1/10 of conventional plant costs

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