Chemical Intermediates | Ascent Chemicals

Chemical Intermediates enjoy a strong value proposition in the key segments they serve. Protected by trade secrets and long application development cycles, these products maintain a high selling price.

They are somewhat protected from low cost product substitution because of stringent standards of product performance, application development complexities, and testing and qualification cycles. Offshore manufacturing has proven risky for many manufacturers who strive to protect their technical advantages with trade secrets enabling a “sweet spot” for US contract manufacturers with unique processing capabilities. Ascent Chemicals has a proven track record with many makers and suppliers of chemical intermediates.

Scenario

Pilot to Production: New product with limited production capacity and manufacturing data. Project required extensive amount of technical coverage.

Goal

Successfully scale up product manufacturing and optimize process efficiency.

Methodology

Provide good technical scale-up and guidance to validate several optimum process assumptions and bring product to market successfully and on time.

Solutions

Developed project parameters to successfully scale up new process.
Provided around the clock technical coverage both in the plant and in the lab.
Consolidated a multi-step process in one vessel to further increase efficiency and reduce costs output.

Process

Polymerization, Solvent Exchange, and Drying

Results

The Ascent Chemicals Staff:

Reduced full process from 6 vessels to 2 vessels – one reaction vessel required for synthesis and one intermediate tank.
Achieved 300% greater throughput efficiency to meet substantial product launch volumes.
Ascent Chemicals sourced specialty materials to scale up to aid in project timeline.