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Continuous Manufacturing and Crystallisation
(CMAC)
Workshop
2nd November 2010
Format of the CMAC WorkshopPart 1: Presentation
• Vision / Rationale for the CMAC Centre and Overview of Research Themes, Mr Ian Laird, University of Strathclyde/NiTech Solutions (Industrial Director of proposed EPSRC Centre in Innovative Manufacturing)
• Question / Answer session with members of the academic team present:
- Professor David Littlejohn, Chemistry University of Strathclyde
- Dr Jan Sefcik, Mechanical Engineering University of Strathclyde
- Professor Xiong-Wei Ni, Chemical Engineering, Heriot Watt University
- Dr Graeme White, Chemical Engineering, Heriot Watt University
- Professor Lee Cronin, Chemistry, University of Glasgow
Format of the CMAC Workshop
Part 2: Breakout Sessions
• Importance of Continuous Manufacturing and Opportunities for Particle Product development - focus on product differentiation rather than process development (facilitated by Craig Johnston, Britest/Fujifilm)
• Who, within Scotland, UK and beyond may be able to contribute to/support/benefit from the Centre (facilitated by Ian Laird, University of Strathclyde/NiTech Solutions)
• Potential TSB Funding opportunities related to CMAC (facilitated by Linda Wallace, University of Strathclyde).
• Feedback from the Breakout Sessions
Continuous Manufacturing and Crystallisation
Vision & Rationale
Ian Laird
Pharma / Chemical Industryis in a lot of
pain
Sustainability
Evolution of Manufacturing
Technology for Chemicals Industry
� Little has changed in 450 years
� The stirred tank reactor is the “normal” approach for manufacture
� Particular challenges around the scale-up of processes
� Expensive, poor control over quality
c.1556 1956 2010
New Paradigm
– Continuous
Manufacturing� Adoption of Lean Manufacturing Principles
� Avoid challenges of large batch by steady continuous process
� Growing levels of interest
� 7 of top 10 global pharma companies and many speciality and
fine chemical companies engaged in this
� New research activity (e.g. Novartis-MIT)
� Benefits include:
� Lower costs – capex, operating costs, working capital
� Greater control over product quality (more predictable scale-up)
� Sustainability – less waste, “greener chemistry”, lower CO2
footprint
� Greater responsiveness – speed to market, adding capacity
� But, no complete solution exists…
CMAC: Centre of Excellence in Continuous
Manufacturing & Crystallisation
Delivered through:� Cross-sectoral and cross-functional
collaborative partnership
� leading academic institutions and major industrial companies.
� Leveraging collective knowledge across the supply chain
� Collaborative funding model to create exceptional business performance & growth
Public Sector
Academia
Industry
The Vision:� World renowned research facility for fundamental and applied research
in continuous manufacturing & crystallisation.
� Driven by Industrial Needs and demand
� Rapid “technology pipeline” from concept -> demonstration –> exploitation.
An Unrealistic Dream…
Or Within Reach?
NiTech Reactor volume reduced
by 99.6% against traditional
approach
The world’s largest patent-
protected continuous pharma API
plant is at Genzyme, Haverhill
Creating Rapid Technology Access
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TRL
Technology
Assessment
& Proving
Pre-
Production
Production
Implementation
UniversityResearch
R & D Industrial Exploitation
Research
CMAC
Development
Deployment
Demonstration
Proven Value Delivery
Experience
Advanced Forming
Research Centre� Industrial demand driven applied
innovation
• Boeing, Rolls Royce, Airbus,
Aubert Duval + others
• Additional involvement from
supply chain and partners
� Activity underpinned by academic
excellence
� £6m of private sector investment
leveraging additional £30m
� Collaboration / Funding / IP
frameworks
What will it do?
– Direct support:
• Member plant and product support
– Generic programme:
• Tier 1 membership contributes to the generic programme, based on Tier 1 member requirements.
• Tier 1 members have free right of use for IP Generated.
– Member specific programmes:
• Tier 1 members can also undertake individual activity
• IP generated is owned by the sponsoring company.
– Technology Fore-sighting:• Future research, disparate markets.
Deliver solutions to enhance
customer’s manufacturing processes.
CMAC Board
CMAC
Leadership Team
AFRC Team
Objectives / Tasks /
Challenges / Priorities
Industry driven
Chair Industry
CMAC
Technical
Board
Research Agenda / Technical Focus
Project proposals / IP Identification
Ideas / Funding Opportunities
(DTI, EU,EPSRC) etc. All sponsoring
Universities
CMAC Key Principles
Governance Model
CMAC Team
Theme Leaders
Research Associates
New post-docs & PhD’s
Day to day management
of centre, research
and University activities.
What might the future look like?
Driven to Meet Needs
� End-user engagement and participation
� Strong alignment of activity
� Proposals created to address requirements
10 Areas of Focus
What is in this for you, your
clients, someone you know?
How can you help?
Manufacturing Operations
Supply Chain
• Manufacturing operations and supply chain configuration
• Management control systems
• Lean / 6Sigma
• Change Management
• Learning from experiences of other industries
• Stimulation of new technologies and solutions
10 Areas of Focus
Influencing Product Design
2
Understanding of kinetics and process,
design of continuous systems
Self-assembly control of particles
including heterogeneous
Provision of new and optimised
materials into the pipeline • Coupling of novel chemistry /
nanomaterial assembly with continuous
crystallisation process
• Backward integration and use of
continuous crystallisation processes to
select better or novel synthetic
pathways to deliver materials into the
manufacturing pipeline
• Focus on synthesis and nanomaterial
assembly (pharmaceutical and
electronic material areas targeted for
proof of principle)
Graphical Summary of two
‘synthetic’ Approaches
5
Development of these continuous systems offers huge flexibility in
providing new or optimised materials for the continuous process
pipeline.
Synthesis will offer access to new materials not otherwise
available.
Self-assembly offers nanoscale control of particles, including
control of architecture and composition.
Prof Colin Pulham
Continuous Manufacture of Robust and New Solid Materials
Prof Xiong-Wei Ni
Dr Graeme White
Prof Chris Rielly
Prof Zoltan Nagy
Understanding Oscillatory
Baffled Continuous
Crystallisation
Direct Nucleation and Model
Predictive Control for
Continuous Crystallisation
direct nucleation control (DNC)
model predictive control (MPC)
Understanding
optimisation
Prediction
demonstration
Moving from batch to continuous..
...brings new demands for
in situ process analysis
New Solutions Require New
Technologies
• use different measurement techniques
– multi-point measurement techniques – smaller, less
expensive, but high information content
• combine different techniques for better process
understanding and modelling
• control strategies for more consistent
manufacturing – tuning the process
• integration of more unit processes in a continuous
supply chain
• demonstration of technology
• access customers
Better Measurement,
Understanding, Control & Prediction
Questions?
Engagement in discussion