SCALE-UP TECHNOLOGIES
SCALE-UP TECHNOLOGIES
Scale-up of production from lab scale to pilot and then to commercial level is always associated with various challenges. It is quite difficult to to maintain the process and the yield in terms of qualitative and qualitative aspects. INNOVEXA’s proven, we have work hard to develop variety of scale-up processes and evaluation capabilities to applied research from bench to the full scale manufacturing to the mass scale.
Scale-up of production from lab scale to pilot and then to commercial level is always associated with various challenges. It is quite difficult to to maintain the process and the yield in terms of qualitative and qualitative aspects. INNOVEXA’s proven, we have work hard to develop variety of scale-up processes and evaluation capabilities to applied research from bench to the full scale manufacturing to the mass scale.
Process Design for Commercialization
Commercialization of a product involves various factors which are critical and fate determining and the complete know-how regarding the same is inevitable. Utilizing our core command and in-depth knowledge we precisely control all the parameters while commercializing a new product or system so that the process shall become highly robust & reliable. While designing the experiment at laboratory level, all requisite are being taken under consideration to mimic the Scale-up strategies utilized for the manufacturing level. Our approach leverages “Design for Manufacturing” (DFM) best practices including a set of strategies, methodologies and tools to ensure that nanomaterials made in the lab will seamlessly and cost-effectively transition to our manufacturing environment.
Techno-Commercial Analysis & Cost Simulation
INNOVEXA’s have developed various technologies where we can prepare nanoparticle of various materials, size, shape and variable Physico-chemical properties for limitless applications. To explain all the technologies ad the materials formed thereof and there potential applications are out of scope of this discussion but we invite our esteemed and inquisitive clients to provide us a chance to explain the field of their interest. while the scientific development of the material is on the go at our facility we simultaneously work on the techno-commercial aspects of the processes involved and the material produced. This is to benchmark the financial and scientific expectations of our client. The methodology includes a holistic approach to address all critical business, technical, engineering, regulatory, supply chain and logistics that ultimately inform the final cost of the nanomaterial.
Using this approach, manufactured price / Cost of Goods Sold (COGS) simulations can be performed early on, and the pathway for scale-up is well-defined prior to the nanomaterial leaving the lab on its way towards manufacturing. This allows for a high degree of confidence that the material can be manufactured at volume and ultimately be integrated into a customer’s product or system successfully.
Scale-Up, Process Validation & Optimization
After the benchmarking of the nanomaterial to be made in compliance to the customer specification is satisfactorily achieved then the developed nanomaterial transitions to INNOVEXA’s scale-up development labs. During this stage the synthetic approach and customer’s specific formula are replicated, stress tested for process validation and optimization. The process of transitioning a nanomaterial from the lab to the manufacturing environment follows a carefully choreographed process created at INNOVEXA to ensure cost-effective materials can be manufactured at whatever scale the customer requires.
Process validation & Optimization focuses on improving the nanomaterial’s economics. Here we evaluate different methods to improve upon factors that impact cost – including chemical yield, volumetric yield, takt time and energy inputs.
Stress testing involves a deliberate and thorough testing of the chemical and process sensitivities of the synthetic method and formula used to make a customer’s material. During this phase we determine breaking points and safe usage limits of the future manufacturing process – with the goal of improving manufacturing reliability and repeatability in the plant.
Along the way quality assurance requirements are set for all raw materials, as well as defining all necessary in-line and post-manufacturing quality control parameters. The final step during the development process is to increase from lab-scale to small-scale production (Pilot Scale)
Upgrade to the Manufacturing
Once the nanomaterials prepared in the lab exhibit all requisite Physico-chemical properties, our lead team immediately move ahead to take the production to Pilot level. During this stage, the production of the material is scaled to one of our pilot manufacturing systems capable of producing multiple times of material volume than the lab scale. All the technical aspects are observed carefully and recorded for the further necessary action. if needed some of the parameters are finetuned to obtain the material with requite physico-chemical properties. Once the material protocol developed for manufacturing has been passed all quality control parameters and accredited – it can then be progressively moved to one of our larger scale manufacturing systems.