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Case study 2: From batch to flow

The problem:

Our client, an Oxford-based SME, had a nutraceutical product in human trials and required a process to deliver first kilos then tonne quantities of product for commercial manufacture. However, they had no process development experience or facilities. The initial manufacturing process was a 5-day batch process with extended reaction times leading to the formation of by-products and manual handling issues associated with a heterogeneous catalyst.

The solution:

iPRD were asked to develop a manufacturing process for this product. Using TSB funding we developed a continuous process using a custom rig built in the iPRD lab. This reduced the reaction time to 20 minutes, thereby decreasing major by-product formation. Furthermore, exposure of the operator to the catalyst was reduced. We were then able to deliver 100 L manufactured product to the client.