Introduction To Laboratory-Scale Processing
The purpose of MicroThermics laboratory-scale processing is to put the manufacturing process into the researcher's hands. This allows them to conveniently formulate using the process, without leaving the lab. It reduces plant trials, and accelerates development. In addition, it places the researcher on a learning curve, constantly becoming more familiar with how their formulas and ingredients interact with the process. As a result, they can make better informed decisions in all stages of development.
Laboratory-scale equipment is distinctly different from pilot equipment. Pilot systems are usually small production systems tailored for specific conditions, with extensive process controls, automation and diversion valves. While they are well suited to manufacturing large numbers of samples for test markets and storage studies, they are costly and cumbersome for research. MicroThermics laboratory-scale equipment is designed to streamline research, cost effectively. Features like diversion valves have been eliminated to streamline processing and accelerate development. Considerable flexibility is built-in so a variety of processing conditions can be duplicated rapidly with very little product, and very little waste.
There are many applications. Because of its convenience and simple operation MicroThermics equipment is used for:
a. Formulation and scale-up
b. Fouling Studies
c. Characterizing the performance of new ingredients. Quality assurance of ingredient blends and flavors
e. Preparation of test sample for in-house studies
f. Engineering studies
g. Fundamental research & kinetic studies
-Bacterial death (TDT)
-Nutrient destruction
-Quality loss
The economics are striking. With some conservative assumptions, we can estimate that development, travel and plant trial expenses for a 10% juice product can easily reach $10,000 per batch. Most MicroThermics' HTST/UHTLab systems cost less than $60,000. The least expensive costs less than $37,000. Even including the cost of installation, these systems can pay for themselves with just a few formulation changes, usually in a matter of days or weeks. This is also true when MicroThermics laboratory-scale processing systems are compared to pilot-scale systems because of their cost and that of the pilot plant and staff. In addition, the cost of waste disposal from pilot and plant trials is reduced significantly.
The economic value of MicroThermics processing systems is even more striking when the impact of product fouling on development timetables and expenses is considered. Full-scale and pilot plant trials involve significant numbers of personnel and down-time when fouling is a problem. MicroThermics processing systems are designed for rapid cleaning, and real-time data acquisition and analysis to provide a means of comparing fouling between different formulae. This allows products to be optimized more quickly in the lab with fewer personnel and hard data to support the results.
The time and expense of arranging plant trials is another area where laboratory-scale processing provides significant cost-savings. Plant trials often involve new standards, procedures and formulae requiring corporate approvals, development of new specifications, analysis, and even establishment of new vendors. These administrative efforts can be the single largest source of plant trial expenses and scheduling problems. Laboratory-scale processing keeps the plant trial in the lab where the most significant technical problems can be addressed quickly, without significant administrative efforts.
Process flexibility is a key feature. While manufacturing processes are often designed for a small range of products and processes for production requirements, this is not true in the laboratory. The objective of laboratory-scale processing is to help researchers work conveniently and reliably with a variety of processes. MicroThermics systems provide flexibility to conduct processes ranging from hot-filling to aseptic and UHT sterilization, and near-aseptic filling.
Product capabilities are important. Companies purchasing MicroThermics equipment are making a significant investment that should support research over a range of products. To further expand the capabilities of our current clients, MicroThermics continuously develops add-on features and modules to expand the range and flexibility of each piece of equipment in the field. These include data acquisition and real-time data analysis, sterile product outlets, automatic filling controls, sterile air hoods equipped for filling, and steam injection modules.
Scale-up is critical. Scale-up of these processes is actually applying the total thermal impact of a manufacturing process to a small volume of product in the lab. The thermal process is not limited to the hold tube, but includes the product's thermal exposure in the heaters and coolers. To reproduce the impact of these processes, it is necessary to have a great deal of flexibility and repeatability which is most easily built into laboratory-scale processing systems.
Many companies have a variety of products being processed through systems with different style heat exchangers (plate, tubular, swept surface). It is not economically feasible to purchase miniature equipment to match each different system, and in fact is rarely necessary. Production heat exchangers are designed for production efficiencies and long production periods. Neither are necessary for development work. For accurate scale-up it is important to identify those processing steps that are necessary to duplicate the process. The objective is to match the total thermal impact or the time-temperature history experienced by the product
MicroThermics laboratory-scale processing systems are built around each client's product and process needs with added flexibility. This allows operating conditions to be altered so the quality from the lab matches that from the plant. In the final result, the process is duplicated and scaled down. This often involves preliminary testing and demonstrations to ensure performance of the equipment and quality of the finished sample. MicroThermics established their testing facility specifically for this purpose.
Training and follow-up support are critical. We recognized that while researchers need this type of equipment, and are familiar with their processes, they may not be familiar with equipment operation. MicroThermics provides free start-up training, and unlimited telephone follow-up with purchases in the US and Canada. In addition, MicroThermics also provides service calls for equipment maintenance, upgrades and training for new employees.
Reliability and proven performance are built-in. Each MicroThermics system is tested to establish and verify its capabilities and reliability before being shipped. Benchmark tests are conducted to establish its temperature capabilities under several different operational modes. Performance tests are conducted with data being recorded over six hours to verify each system's temperature stability. Results are included as part of the operators manual and our in-house client records. If a problem develops, these records provide the most effective means to determine its severity, cause and solution.
Purchasing MicroThermics laboratory-scale processing system is usually a multi-level process. This equipment is a completely new product category, and interests several departments, usually at many levels. Research and development see it as a way to test new formulas more rapidly and accurately, and show processed samples to marketing and in-house taste panels. Manufacturing and operations personnel see it as way to increase production time and reduce down-time for plant trials. Management sees it as a way to accelerate development with more streamlined and effective research, reduced travel and plant trial expenses.
