Case Study: Specialty Intermediate

Situation:
Customer had products competing for the same production asset capacity, unable to supply high volume core product demand.

Goal:
Transfer niche technology to DTI and allow customer to streamline internal manufacturing with no CapEx required.

Methodology:
Applying DTI thorough new product stage-gate introduction process key critical to quality metrics is captured.

Solutions:
The DTI Staff:

  • Immediately initiated pilot plant trials to ensure process parameters were clearly defined and validated.
  • Moved quickly from plant trials to full scale production.
  • Instituted customer’s process knowledge through regular team meetings. 

Process:
Solid and Liquid Reagents, Specialized Extraction and Drying/p>

Results:

  • Customer ability to maintain global supply met.
  • Increased specialty intermediate daily capacity 500%.
  • No CapEx deployed by customer allowed for core product line growth.

 

Case Study: Horizontal Reaction

Product development is a key step in validating market segment fit. When supply must be met and manufacturing plans are still undefined, an organization like DTI can add security to a supply chain. The technical knowhow of DTI comes with every project, primarily focused on horizontal reactor technologies.

Situation:
New product with step-change in market demand. Current process utilized typical vertical reaction technology generating low yield.

Goal:
Successfully meet increased demand in short timeframe free font utilizing more efficient horizontal reaction technology.

Methodology:
Harness DTI’s experience with horizontal reactors to develop a more efficient process. Ability of horizontal reactors to operate in viscosities near 1-million centipoise.

Solutions:

  • Developed new process and formulation.
  • Easily met client’s budgetary cost targets for production.
  • Complemented Pilot to commercial scale validation work in 5 months to begin supplying the growing market with certified material.

Process
High Viscosity Liquids + Solids Reaction, Drying, and Particle Sizing

Results:
The DTI Staff:

  • Increased batch yield by 350%.
  • Reduced solvent usages by 60% and improved cycle-times by 75%.
  • Increased yearly output ten-fold.