Design Smart
Choose process elements that are scalable and/or modelable
Mixers
Replace high shear mixers with static mixers that are scalable and can be modeled.
Batch and CSTR reactions are also scalable and modelable.
Scale Down
Avoid running tests at full scale. Take the time to find the smallest scale that allows you to be representative of manufacturing results.
Build your test setup in a flexible skid that allows various parts to be clamped together.
Assess your process to understand the key components. Cut your test setup down to the essential parts that you are testing.
Standardize
Standardize your process between manufacturing plants to allow for one scale up test skid and one model. It minimizes the amount of work that needs to be done to validate formulas.
Model
Use modeling to avoid doing physical tests.
Use CFD modeling to do your mixing scaeup.
Use gPROMS or Matlab to model reactions.
Don’t waste your waste
Pilot plant and manufacturing scale trials produce tonnes of waste. Look for ways to reuse that waste.
Share with your colleagues
Start a database of available waste that can be shared.
For example, perhaps you’ve made some finished product in a mixing trial. Let your colleagues know that that waste product exists. Someone might need some finished product samples for perfume cross-over testing, to run a pressure drop test or to validate a new piece of equipment or setup. Then they don’t need to make these products from scratch. It saves time and raw materials.
Sell to other companies
Your waste is someone’s gold. Perhaps there are parnterships that can be formed with local businesses who can use your waste material.
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