Process Scale Up
Project challenges
The production of CNC based pigments requires the precise preparation and processing of the materials. Existing lab-scale processing techniques are labour intensive, lack robust quality controls and are uneconomical at production scale.
Business challenge
Product Innovation
Sector
Manufacturing
Technology or capability
Product Design
Material Characterisation & Process Scaling
The MTC identified and validated enhanced processing and measurement techniques for the precise controlled treatment of cellular nanocellulose (CNC) suspensions. Through a rigorous engineering approach, the MTC reduced processing times, improved processing control and increased production capacity.
The Challenge
The production of CNC based pigments requires the precise preparation and processing of the materials. Existing lab-scale processing techniques are labour intensive, lack robust quality controls and are uneconomical at production scale.
The MTC was engaged to research, identify and validate process measurement techniques to permit the suspension formulation state of the CNC to be determined.
Additionally, MTC engineers identified and validated alternative processing equipment and methods to reduce labour requirements and increase production capacity.
MTC's Solution
- The MTC conducted a comprehensive market and literature review to determine potential analysis equipment and techniques.
- A series of validation experiments were conducted to evaluate the performance and practicality of potential solutions.
- Acquired pilot-scale production equipment for enhanced suspension processing. Validated continuous in-line processing for production-scale compatibility, demonstrating substantial benefits in labour, productivity and energy requirements.
The work completed by the MTC provided us with significant advantages for the quality and economic competitiveness of our products. The unique range of engineering capabilities at the MTC has allowed them to quickly deliver innovative solutions to our scale-up challenges.
Dr. Simon Kew, Chief Operating Officer at Sparxell
The Outcome
- Identification and verification of a rapid, low-cost CNC suspension measurement technique, facilitating consistency of pigment production.
- Significant reduction in processing time and labour requirements, demonstrating viability for commercially economic scale.
- >100x increase in production capacity.
- Implementation of in-process energy monitoring system.
Benefits to the Client
- Improved process monitoring and control capabilities facilitating reduced costs, quicker time-to-market and improved product quality.
- Rapid access to multiple advanced analytic and measurement facilities.
- Verified demonstration of commercially-scalable process compatibility.
- Significant reduction in processing cost and re-processing requirements.
The innovative methods the MTC investigated demonstrated that our material could be produced at larger volumes, using a cost competitive system while maintaining quality.
Dr Benjamin Droguet, CEO at Sparxell