Process development tools in the context of Quality by Design (QbD) allow a holistic evaluation of chemical synthesis and unit operations. Including Process Analytical Technology (PAT) in the early-stage development provides a significant advantage in process control.  

Flexibility – Easy Changeover 

Interchangeability of plant modules will be possible with standards like Module Type Package (MTP) for vendor-independent integration, similar to USB at the computer. Future chemical plants will provide uniform processing according to the chemical requirements of a process, with intensified mass and heat transfer and each molecule experiencing the same processing conditions. 

Cost Efficiency – Focus on Value Generation 

Focusing on value generation in the processing industries could lead to significant changes in how manufacturing will be done in the future. Applying this concept in the chemical industry identifies value generation for batch reactors during the synthesis of the molecule while filling and heating up as well as emptying and cleaning only produces effort and costs. A better synthesis reduces the workup effort (Right First Time).  

Speed – Time to Process 

Like the automotive industry in the past, the realization of processing plants will move towards using platform strategies. Approximately less than a third of a chemical plant is usually specific to a certain process or chemical reaction. Package units like feed modules, chillers, and some downstream unit operations are universal and will be bought or rented off the shelf in the future. MTP will enable the connection between modules from different vendors to quickly set up a temporary plant for certain manufacturing tasks.  

Case Study – Modular Manufacturing 

Process intensification and continuous manufacturing enable novel ways to produce fine and pharma chemicals for small and medium-size products and intermediates. Microinnova Engineering recently built a continuous plant designed for such applications, consisting of several modules in a walk-in fume hood environment. 

Paradigm Shift  

Continuous manufacturing and process intensification are generating a huge paradigm shift in terms of preferred manufacturing technologies and methods. Three fundamental paradigms will be the core drivers for new processes in the future. The first is to identify the needs of a reaction or a process and to fulfill these needs with a wide range of different technologies and methods in the best possible way. The second is to enable the same processing conditions for all molecules. The third is to optimize mass and heat transfer. Processes following these paradigms will generate superior advantages for a more economic and sustainable future.