Process Development & Industrial Optimization

Process Development & Industrial Optimization

Industrial biotechnology is an industry that consumes a huge amount of resources, including raw materials, water resources, energy, chemicals, and discharge a large amount of waste; Therefore, how to optimize existing industrial facilities and design new process is an eternal subject in this industry.

Process Development

SmarSEP provides two types of process development experiments.

1. Provide laboratory-scale and pilot facilities:  Based on experience from experts, directly conduct “trial and error” type process experiments on product. This type of experiment is good enough for quickly determining the basic feasibility of the process,  which was applied by the vast majority of companies in the industry. However, this methodology is difficult to ensure that the obtained operation parameters are optimal.

2. Provide experiments to determine parameters of thermodynamics, dynamics, and fluid dynamics: This type of experiment starts from a more fundamental understanding of separation mechanism and provides the basic parameters required for mathematical simulation of the process, in order to establish a mathematical model for a specific process. Once the model is established and calibarated, it can be easily used to predict and optimize the process.

Resin evaluation & Screening

As the most critical separation medium in the field of industrial biotechnology, resin's structure and performance directly affect whether the industrial process is efficient and competitive. However, it is difficult for us to objectively evaluate the differences between resins from different manufacturers, because different resins have specific structural and their thermodynamic and kinetic properties are different. Therefore, the optimal separation parameters that need to be used during the separation process will be different; and It is obviously unreasonable to use the same set of parameters to measure different resin performances.

Based on specific separation purpose, we can measure the thermodynamics, kinetics and hydraulic parameters of different resins, by establishing mathematical models based on these parameters, and subsequently verify the separation performance through process experiments, we can truly have comprehensive and accurate evaluation of the resin. thus identify the best adaptable resin for a specific separation purpose!

Industrial Optimization

In the industrial biotechnology market, a large number of physical and chemical processes are applied, including enzyme reactions, ion exchange, industrial chromatography, crystallization, etc. Based on traditional “trial and error” methodology, we have almost reached the limit if purely by personal experiences;

We are willing to cooperate with the world's top science and technology companies, based on the first principles of the process, to essentially rethink each of the processes, and combined with modern mathematical tools and computing power, it is possible to predict and optimize hundreds of process conditions in very short time, in order to make every industrial unit operate in optimum conditions; at the end, we can improve the purity and yield, as well as reduce chemical and energy consumption for existing industrial systems.

Digital Twin

Digital twin technology has penetrated into various fields. The application of this technology has not only played a positive role in production efficiency, but also made tremendous contributions in safety, innovation, environmental protection, and sustainability.

The application of digital twin technology enables production enterprises to monitor and optimize the production process in real time. Through digital twin models, parameters on the production line can be adjusted in real time to achieve optimal production efficiency, which helps to reduce production costs and improve product quality.

Digital twin technology makes remote operation and maintenance possible, which means engineers and operators can monitor and manage production processes from remote locations, reducing the risk of exposure to hazardous environments. Meanwhile, expert teams can more quickly reacte and solve problems.

With the help of the numerical simulation software developed by YPSO FACTO, we could perform digital twin on some key equipment in the field of industrial biotechnology, such as enzyme reactions, chromatography systems, ion exchange systems, etc., thereby creating the necessary conditions for the digital twin of the entire factory!