NANOMATERIALS a complete analysis of each batch , serving as a quality checkpoint and ensuring the unique attributes of nanomaterials are preserved and consistent .
The synthesis of certain nanomaterials involves precursors or reagents that can be extremely sensitive to external conditions like light , air or temperature fluctuations . The confined environment of batch reactors ensures the stability and efficacy of these precursors throughout the synthesis process , crucial for the desired nano-properties .
While the use of nanomaterials by industry is growing exponentially , many applications are still in nascent stages or cater to niche markets . The investment required for continuous production systems often is not justified by the demand or volume . Batch processes , on the other hand , offer modularity , scalability and adaptability tailored to the everevolving world of nanomaterials
While batch processing ’ s dominance in nanomaterial manufacturing arises from a confluence of factors , the unique challenges and requirements presented by the nanoscale play a central role . As the science of nanomaterials advances and as we continually push the boundaries of what is possible , the adaptability and precision of batch processing will remain invaluable .
Hybrid approach
However , there is always room for improvement . Hybrid batch manufacturing integrates both batch and continuous processing techniques , aiming to harness the strengths of each while mitigating their limitations .
By strategically employing each method at specific stages , manufacturers can achieve optimised results . Cerion Nanomaterials exemplifies this approach , adopting it in response to its customer base , which increasingly seeks enhanced processing capabilities and larger production volumes . The key advantages are integrating stages , flexibility , scalability , quality and control , and safety and environmental factors .
In hybrid systems , specific stages of a process might be continuous , while others remain batch-oriented . For example , a raw material could be processed continuously until a particular intermediate is formed , after which the material might be subjected to batch processes for final modifications and purification
Hybrid systems offer operational flexibility . For instance , in chemical synthesis , the initial reaction stages are often more suitable for batch processing where the reaction conditions can be precisely controlled and adjusted in real time , whereas subsequent post-processing of the nanomaterial , such as calcination , might be more suitable for continuous processing due to steady-state conditions , better heat management and improved yield .
Combining continuous and batch modes can also make scale-up more straightforward . The continuous stages can be scaled by extending operating times , while batch stages can be scaled by volume or through parallel batch units .
The continuous segments of hybrid systems can provide consistent quality due to steady-state operations . Batch segments , meanwhile , allow for tighter control over specific stages ,
accommodating processes that might be difficult to maintain continuously .
By integrating continuous processes where they are most advantageous , one can achieve reduced operational costs , better resource utilisation and potentially higher throughput . The batch stages can cater to processes that may not be economically viable to run continuously , due to upfront engineering investments , equipment costs , set-up times or intermittent demand .
Summary
While the broader narrative in speciality chemical and nanomaterial manufacturing has been largely dominated by batch processing , it is important to recognise that there are always exceptions that challenge the norm . There are indeed certain materials that are effectively produced through continuous processes .
However , continuous processing remains an outlier in this domain . For a majority of speciality chemicals and nanomaterials , the complexities of their synthesis , combined with the need for precise control and adaptability , often render batch processing a more suitable , pragmatic and economically appropriate choice both for the manufacturer and more importantly , their customers . ●
References 1 . An FDA Self-Audit of Continuous Manufacturing for Drug Products . US FDA , 31 July 2023 . https :// www . fda . gov / drugs / cder-small-businessindustry-assistance-sbia / fda-self-audit-continuous-manufacturing-drug-products #:~: text = At % 20the % 20start % 20of % 202022 , finished % 20 solid % 20oral % 20drug % 20products . 2 . R . Chen et al ., Bioprocess Online , December 2022 : https :// www . bioprocessonline . com / doc / where-do-we-stand-on-adopting-continuousmanufacturing-for-biologics-0001 3 . K . Jhamb , Continuous Manufacturing in Pharmaceuticals : Implications for the Generics Market . Drug Development & Delivery : https :// drug-dev . com / continuous-manufacturing-continuous-manufacturing-in-pharmaceuticals-implications-for-the-generics-market / 4 . J . Pelley , C & EN , 12 February 2022 : https :// cen . acs . org / policy / chemical-regulation / Number-chemicals-commerce-vastly-underestimated / 98 / i7 5 . OECD Environmental Outlook for the Chemicals Industry , 2001 : https :// www . oecd . org / env / ehs / 2375538 . pdf
J j
Landon Mertz
CEO
CERION NANOMATERIALS landon . mertz @ cerionnano . com www . cerionnano . com
JAN / FEB 2024 SPECCHEMONLINE . COM
53