Case Study: Chemical Intermediates

Chemical Intermediates enjoy a strong value proposition in the key segments they serve. Protected by trade secrets and long application development cycles, these products maintain a high selling price. They are somewhat protected from low cost product substitution because of stringent standards of product performance, application development complexities, and testing and qualification cycles. Offshore manufacturing has proven risky for many manufacturers who strive to protect their technical advantages with trade secrets enabling a "sweet spot" for US contract manufacturers with unique processing capabilities. DTI has a proven track record with many makers and suppliers of chemical intermediates.

Situation:
Pilot to Production - New product with limited production capacity and manufacturing data. Project required extensive amount of technical coverage.

Goal:
Successfully scale-up product manufacturing and optimize process efficiency.

Methodology:
Provide good technical scale-up and guidance to validate several optimum process assumptions and bring product to market successfully and on time.

Solutions:

  • Developed project parameters to successfully scale-up new process.
  • Provided around the clock technical coverage both in the plant and in the lab.
  • Consolidate a multi-step process in one vessel to further increase efficiency and reduce costs output.

Process
Polymerization, Solvent Exchange, and Drying

Results:
The DTI Staff:

  • Reduced full process from 6 vessels to 2 vessels - One reaction vessel required for synthesis and one intermediate tank
  • Achieved 300% greater throughput efficiency to meet substantial product launch volumes
  • DTI sourced specialty materials prior to scale-up to aid in project timeline

 

Case Study: Good Manufacturing Practice (GMP)

Nutritional food value is becoming increasingly important due to heightened consumer awareness. The goal was to deliver new nutritional food technology without compromising download fonts taste for the consumer. New manufacturing techniques are being developed as companies bring new products to market.

Situation:
A customer needed to make sample quantities of a new food additive technology.

Goal:
Generate adequate material under GMP conditions in a timely manner.

Methodology:
DTI applied 25 years of regulatory and manufacturing experience of GMP products.

Solutions:
The DTI Staff:

  • Successfully scaled-up new additive process for particle surface treatment into semi-commercial quantities.
  • Identified and solved particle classification issues to avoid delays for client’s market launch.
  • DTI sourced specialty materials prior to scale-up to aid in project timeline.

Process:
Encapsulation, Mixing, Drying, and Particle Sizing

Results:

  • Successful product launch including global sales
  • Unique supply-chain for specialty ingredients providing completely stabilized finished product to support broader product growth.