Consulting project to assist client with increasing manufacturing capacity of a plant growth regulator made by fermentation. Developed design basis and pro forma production plan based on projected future year sales. Developed detailed fermentation, harvest and recovery simulation models of the existing process and determined the maximum capacity of each piece of equipment. Used simulation models to demonstrate the downstream processing train had sufficient capacity with addition of only a single larger filter/dryer. Developed scope of work for overall project including addition of raw materials storage, fermentor and filter/dryer and required process automation changes to integrate new equipment into the existing plant. Documented all of this in a draft user requirements specification for the client.
| Unit operations: Fermentation, Sterile nutrient dosing, Ceramic microfiltration, Ion exchange separation, Reverse osmosis filtration, Forced circulation evaporation, Crystallization, Nutsche filter drying, Continuous media sterilization |
| Product: Plant growth regulator |
| Company: Confidential Client |
This client had a forecast demand for this product of twice their current production rate and retained Urna Vitae to assist with determining how best to debottleneck the existing process. Their existing downstream processing train for this product was composed of a series of unit operations that processed a fermentation batch in several recovery sub-batches. The capacity of each unit operation varied, with some units having considerable excess capacity. This is not uncommon, as often equipment is sized based on a manufacturer’s standard size or based on an earlier process design.
I reviewed the capacity of each piece of equipment and developed detailed process simulation models for the fermentation, harvest, and recovery that maximized the capacity utilization of each piece of equipment. This analysis found that if recovery sub-batches were pooled in the final procedures to maximize the equipment fill, most of the recovery train had sufficient capacity for the increased production rate. With this revised process, the client needed to add just another fermentor with additional glucose storage and a larger Nutsche filter to double their production rate.
To document the design basis, the modeling results and the scope of work required to specify, procure and install the equipment, I then compiled all of this information into a draft user requirements specification for the client.