Process Development

Creating Safe, Efficient and Cost-Effective Manufacturing Processes

Expert Advice to Optimize Your Syntheses

Process development plays a critical role in chemical manufacturing, as it involves designing and optimizing the manufacturing process for a specific chemical product into a safe, sustainable, robust and cost-efficient chemical process, yielding a high-quality product.

What is Process Development?

Chemical process development encompasses the design, creation, and optimization of chemical processes for producing a specific product or compound. This involves combining chemical and engineering principles to establish a process that is safe, efficient, and economical.

Process development is crucial for launching a new product, demanding a thorough understanding of the underlying chemistry, as well as the necessary equipment, raw materials, and process controls for production. Furthermore, it must address the environmental impact of the manufacturing process, aiming to minimize waste and reduce energy use.

Objectives of Process Development

The goal of process development is to create a safe, efficient, and cost-effective manufacturing process that can produce a high-quality product on a commercial scale. This process involves identifying the critical process parameters, optimizing the process conditions, and ensuring the product meets all quality and safety requirements.

Steps of Process Development

1. Consultation with Customer

Before commencing the Process Development process, it's crucial for HFC to understand what the customer wishes to achieve.

2. Research and Development

This includes performing experiments and analyses to determine the chemical reactions and processes needed to create the desired product.

3. Process Design

The findings from the research and development phase inform the creation of a process design that outlines the equipment and conditions necessary for the production process.

4. Pilot Plant Scale-up

The process is subsequently tested at a pilot plant scale to confirm its feasibility for scaling up to a commercial semi-industrial level.

5. Optimization

The process is refined to boost efficiency, cut down on waste, and lower costs.

6. Commercialization

Once the process has been thoroughly optimized and tested, it can be commercialized and expanded for large-scale production.

Challenges of Process Development

Processes that can be easily managed at a small scale in the laboratory often require substantial modification to be feasible at a large scale in manufacturing settings. This is where process development plays a crucial role.

It serves two primary purposes: firstly, to produce increasing quantities of the active pharmaceutical ingredient (API), scaling from grams to semi-industrial scales over time to support ongoing trials and other development activities such as formulation. Secondly, process development refines the "recipe" to facilitate large-scale production in a timely, safe, and cost-effective manner.

Creating new synthetic processes involves a diverse array of chemical methodologies. These methods have been fine-tuned to ensure the creation of robust and efficient synthetic processes. Employing them demands a deep understanding of process mechanisms and reaction rates, determined through comprehensive analytical techniques. Moreover, knowledge of the available technology parameters for scaling up these processes is essential for managing this intricate task.

Frequently Asked Questions

What information do I require before submitting a Request for Quotation (RFQ)?

Generally, you should give as much information as you can, because the more specific you are with your request, the more accurately we will be able to quote you and fulfill your needs. In general, we would require the following information:

  • Product Name
  • Molecular Formula (if known)
  • CAS No. (if known)
  • Quantity Required
  • Purity
  • Application
  • Any references to publication or literature references (if available)
  • Reaction Scheme

Upon providing the customer with the 'know-how', is HFC able to offer a continuous supply of the product to the customer?

If requested by the customer, we would treat the request for ongoing supply of a process we developed just like any other RFQ, wherein we will evaluate the commercial value of the request against our internal metrics and provide a quote accordingly.

For example, should a customer not have the required facilities to manufacture a chemical compound, they may request HFC's Process Development services and receive the 'know-how', and request that HFC manufacture the product for them until they have the required facilities to manufacture it themselves.

Will I be provided with a Non-Disclosure Agreement (NDA)?

All queries are dealt with strict confidentiality, however, if you would like to enter into a Non-Disclosure Agreement (NDA), please let our team know to be provided with one.

Process Development Enquiry Form