The Benefit of a Pilot Plant in Speeding the Commercial Process

Have you ever asked yourself why you needs a pilot plant for research and development? In fact, a number of processes are scale dependent. It can be quite a challenging experience to transition from small-scale operations to a large scale production plant. The transition needs to be smooth but the initial setting up can be a big scare.

A huge production plant is sometimes built based on information which is gathered at the small unit. However, the kinetics may differ considerably and the reactions may not be up to par. However, sometimes the best laid plans may not go according to plan. The worst case scenario could be that uncontrolled heat build-up could lead to abnormal reactions and possible explosions even if some materials are corrosion-resistant.

This cannot be attributed to human error, rather it could be a process that went wrong. The process takes a different turn when there is a change. It is also not possible at times to forecast these problems as they may be too complex to comprehend. A pilot plant can be very helpful as far as minimising error is concerned. Therefore, experiments can be studied more thoroughly without posing a major risk. The pilot plant does not only provide data before increasing scale of production, it serves other function. This include:

Corrosion resistant

1. It helps in making an authentic comparison with commercial grade raw material against the grade counterpart in the laboratory. During a lab study, the use of raw material and catalyst is not very big. Therefore, a highly pure grade can be used for the experiment. However, when it comes to a production plant, using pure materials would be feasible. Commercial grade material is best used.

2. The plant can be used for the production of small product quantities which can be used as raw material for market testing. The plant can be used to produce quantities which can be used to study the reaction process which might follow. It is one of the best ways to test a product in the real market. Samples can be handed out to customers to gauge their reactions

3. The quality of waste and by-products can be studied, in addition to assessing their saleability.

4. Waste generated can also be studied to determine if waste treatment is necessary. This will help understand the economics associated with the process.

5. A pilot plant will help come up with a more detailed mass balance. It will allow companies to give yield estimates. Lab experiments normally generate a sizeable number of erroneous mass balances due to the fact that quantities are much smaller. When it gets down to a full-blown production, the values are much higher.

6. A pilot plant will give you the liberty of producing specialty chemicals that may be appreciated by a more niche market. Therefore, it can safely be said that a pilot plant can help a business go from lab testing to high production plant faster without posing much of a risk. It also aids in keeping in focus the economics involved in setting up a large scale production because corrosion-resistant products may not translate to saleability.

Pharma Glass Advantage

Have you ever wondered why glass bottles are the preferred choice in the pharmaceutical industry? There are a number of reasons why pharma glass is popular. One of the main reasons glass is used for packaging is because it does not react adversely with the contents inside it. Glass is more or less classified as an inorganic product that is made up of sustainable and natural raw materials. 

Glass is also chemically inert and pure and is, therefore, a safer bet. It is also the preferred, and a popular, choice among consumers. Some of the other important properties of glass, namely transparency and recyclability, make is the perfect packaging material for pharmaceutical products. This apart, the recyclable nature of glass does not go against environmental norms. It is the best substance to use. Therefore, pharma glass does its bit to preserve the environment. 

pharma glass

A large number of glass manufacturing units make use of natural gas as fuel and are therefore non-polluting. In fact, once liquids or other chemicals are mixed in industrial agitators, they can be easily transferred to a glass container. In fact, it is interesting to note that glass is the only packaging material to be rated “generally regarded as safe” (GRAS) by the US FDA. If you are still not convinced, here are some of the main advantages glass enjoys over PET where pharma product packaging is concerned. Here are some of the main benefits listed:

Packaging made from glass has the ability to handle vacuum as well as high pressure sealing. It also acts as a protection against oxygen invasion and moisture. It also safeguards from bacteria and spoilage. 

One of the biggest advantages of glass is the fact that it can be customised to protect against damaging ultraviolet light. Therefore, it ensures product taste and purity. There have been a number of experiments as well as research that points to the fact that glass has a longer shelf as compared to other packaging material. This is another major reason why it has the vote of confidence from a number of consumers.

A number of studies and research across the globe have stated that glass is the safest choice for consumer health and the environment – a significant reason why it is the preferred product packaging material. 

Consumers swear by glass packaging for a number of reasons. Glass helps protect the quality of food and beverage – close to 78%

Glass preserves a product’s flavour and taste (75%)

Glass maintains the healthiness and integrity of foods and beverages – around 82%

The usage of glass is one of critical importance, especially in present times. This is because our actions have had an adverse effect on the environment. This has caused an alarm all over the world. The use of glass for packaging is in the interest of the human race. Therefore, it is of vital importance to preserve and improve the environment. When a chemical or other substance comes out of an industrial agitator, you know where to put it in.