Process Development and Scale-up Production
This is another area of our business that has seen significant growth in the last few years, so much so that we seriously considered building our own larger-scale production facility to meet the increased customer demand.
It has become a common occurrence that we produce a research quantity of a material - a few hundred grams, and then within a matter of weeks, 100kg plus of the material is produced and delivered.
Where product requirement exceeds our current capacity, we work, with the customer's permission, with carefully selected partners at a larger scale to ensure a successful outcome.
This year we have developed several of our projects to multi-ton production scale.
Transferring a process from lab scale into semi-bulk or bulk production is often one of the more difficult aspects of chemical production. Even with a good production process semi-bulk volumes are tricky amounts to produce - too large for some companies and too small for other companies to handle efficiently. At ProSynth initial speed of response, project evaluation, competitive pricing and lead times remain an integral part of our semi-bulk and bulk production service.
At ProSynth a number of the team have considerable experience in semi-bulk production. Pure research chemists are not always aware of the equipment constraints or pressures of the larger scale production environment, and to a degree why should they be, the parameters are often quite different. Availability of raw materials, process robustness and environmental impact become more important decision factors.
Ever increasing regulation and legislation, health and safety, environmental, and shipping requirements to name but a few, require strict compliance, the dreaded red tape and paperwork, and this too is an area that ProSynth take very seriously indeed.
The majority of our processes are designed with scale up in mind and many of our processes have been successfully transferred to other companies.