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.
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