Case study · Plastics, Chemistry & Laboratory
Scale-up and technology transfer of a modified polymer system
In the development laboratory of a specialty chemicals manufacturer, a highly resistant polymer-based coating formulation had been successfully formulated. When attempting to transfer the process system to industrial production scale, however, massive viscosity problems and incomplete reactions occurred, leading to unusable batches.
Technical management of the technology transfer (scale-up) at the interface between development laboratory and production, with the aim of establishing the process reliably in the large reactors.
Analysis of the critical process parameters (CPPs) directly at the mixing plants. The agitator geometries were adapted and a step-by-step upscaling protocol defined.
Temperature control during the exothermic reaction phase was recalculated and closely validated in the laboratory with intermediate samples. Plant operators were trained directly at the machines.
Result
The process was successfully transferred to the large-scale plant. Viscosity tolerances are now reliably met, completely eliminating costly faulty batches. The technology transfer was fully documented and handed over to the internal production team.
FAQ
Frequently asked questions
Why did the transfer from laboratory to production fail at first?
Because of massive viscosity problems and incomplete reactions at production scale, which led to unusable batches.
How was the process stabilised for the large reactors?
The critical process parameters were analysed directly at the mixing plants, the stirrer geometries adapted and a step-by-step upscaling protocol defined. The temperature control of the exothermic reaction phase was redimensioned and validated with intermediate samples.
What was the result of the technology transfer?
The viscosity tolerances are now reliably met, faulty batches have been eliminated completely, and the technology transfer was handed over to the production team with complete documentation.
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