The Challenge

Initial studies carried-out at Lucideon on fresh and aged product batches, produced on both original and new processing lines, provided vital insights to the client enabling their scientists and engineers to better understand how the structure, rheology and stability of their pastes were influenced by the manufacturing process. In this 2nd Phase to optimise the process, Lucideon was asked to define a series of production runs according to Factorial Experimental Design which could be carried-out at pilot-scale in order to evaluate, quantify and optimise key process variables.

What We Delivered

Lucideon experts assessed the manufacturing process and worked with the client to determine suitable ranges for the process variables taking into consideration how they were likely to change product performance and stability. An FED study was defined by Lucideon and the experiments performed on-site at the client’s production facility. Measurements of key product performance criteria were undertaken and the responses provided to Lucideon for analyses using advanced Design of Experiments (DoE) software tools.

Value to the client

The FED study generated and analysed by Lucideon in partnership with the client enabled quantification of the key process variables, their strengths and interactions. The key outcome was the identification of optimal process parameters for the new production line necessary to achieve optimal product performance. Through Lucideon’s FED study, the client was able to better understand their new production line, to quickly and effectively fine tune parameters to optimise product quality in terms of performance and long-term stability and, therefore, to realise their full production capacity.

To learn more of the first phase of this case study please click here.