Scale-up support
We take your innovative ideas one step closer to industrialisation
At SPECIFIC POLYMERS, all of our research and development activities are carried out with an industrial perspective. Accordingly, when a product developed by our teams shows promising performance for our customers’ or partners’ application, we propose scale-up support. It is important for us to be able to give them a hand in taking the first steps towards the industrialization of this innovative technical solution.
ACTIVITY CONTENT
Evaluation
Assess the compliance of synthetic pathways with a pilot scale production
Optimization
Adjust the synthesis processes at intermediate lab scale (50g-250g)
Transfer
Work with toll manufacturers for pilot-scale production (10kg – 50kg scale)
From laboratory to pilot-scale synthesis of your R&D products
Evaluation of synthetic pathways
Assess the exothermicity, productivity, cost, safety and sustainability of the process
Process optimization
Adapt synthesis conditions to make them compliant with a pilot-scale production
Intermediate scale-up
Evaluate optimized protocol at 250g-500g scale and validate reproducibility
Product conformity
Check that optimized protocols do not affect the final performance and outline final product specifications with the customer
Detailed process book
Provide the toll manufacturer with a detailed process book describing optimized synthesis protocols and product specifications
Transfer to the toll manufacturer
Connect with the toll manufacturer and guarantee project continuity
From laboratory to pilot-scale synthesis of your R&D products
Evaluation of synthetic pathways
Assess the exothermicity, productivity, cost, safety and sustainability of the process
Process optimization
Adapt synthesis conditions to make them compliant with a pilot-scale production
Intermediate scale-up
Evaluate optimized protocol at 250g – 500g scale and validate reproducibility
Product conformity
Check that optimized protocols do not affect the final performance and outline final product specifications with the customer
Detailed process book
Provide the toll manufacturer with a detailed process book describing optimized synthesis protocols and product specifications
Transfer to the toll manufacturer
Connect with the toll manufacturer and guarantee project continuity
OUR MAIN SKILLS
To ensure the production scale-up of a specified product, SPECIFIC POLYMERS first studies the pre-selected experimental conditions in detail using a multi-step approach:
- (i) evaluation of the exothermicity, productivity, cost, safety and sustainability of the initial experimental parameters, at each synthetic step
- (ii) validation or invalidation of the parameters of the synthesis and implementation of curative actions to adjust the experimental conditions to a pilot-scale production, and
- (iii) scale-up targeted products at an intermediate scale (500 g – 1kg) and assess the synthesis reproducibility.
Deviations, risks and other undesired parameters are evaluated and resolved to provide the most detailed process book possible that gathers all optimized synthesis and treatment protocols as well as the final product specifications. In that sense, we ensure a good scale-up support at each step of the industrialization.
When the synthesis processes are optimized at this scale, SPECIFIC POLYMERS contacts its network of toll manufacturers to identify the best partners to work with based on the chemistry, targeted volumes and production requirements of the customer. Once the toll manufacturer is identified and the appropriate commercial agreement signed, the toll manufacturer takes over the synthesis process in its own laboratories to validate compliance with a pilot-scale production of the optimized protocol. Finally, pilot-scale production is scaled up to reach quantities from 10kg to 50kg. Depending on the needs of the customers and the toll manufacturer’s abilities, additional studies such as manufacturing cost evaluations, life cycle assessments or evaluations of process safety can be undertaken.
When the synthesis processes are optimized at this scale, SPECIFIC POLYMERS contacts its network of toll manufacturers to identify the best partners to work with based on the chemistry, targeted volumes and production requirements of the customer. Once the toll manufacturer is identified and the appropriate commercial agreement signed, the toll manufacturer takes over the synthesis process in its own laboratories to validate compliance with a pilot-scale production of the optimized protocol. Finally, pilot-scale production is scaled up to reach quantities from 10kg to 50kg. Depending on the needs of the customers and the toll manufacturer’s abilities, additional studies such as manufacturing cost evaluations, life cycle assessments or evaluations of process safety can be undertaken.
Need more information? Interested in our Scale-Up Support service?
We will be glad to discuss with you! Fill in the form below to contact the Scale-Up Support Manager.