Design & Development of Biological, Chemical, Food and Pharmaceutical Products

310 Pages·2007·7.5 MB·English

by  Johannes A. Wesselingh

Design and
Development
of Biological, Chemical,
Food and
Pharmaceutical
Products
Design and
Development
of Biological, Chemical,
Food and
Pharmaceutical
Products
J.A. Wesselingh
EmeritusProfessorofChemical Engineering,
University ofGroningenandTechnical University ofDenmark
Søren Kiil
AssociateProfessor,DepartmentofChemical Engineering,
Technical University ofDenmark
Martin E. Vigild
AssociateProfessor,DepartmentofChemical Engineering,
Technical University ofDenmark
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LibraryofCongressCataloging-in-PublicationData
Wesselingh,J.A.
DesignandDevelopmentofBiological,Chemical,FoodandPharmaceuticalProducts/J.A
Wesselingh,So¨renKiil,MartinE.Vigild.
p.cm.
Includesbibliographicalreferencesandindex.
ISBN978-0-470-06154-1
1. Biochemicalengineering.2. Newproducts.3. Design,Industrial. I.
Kiil,So¨ren.II.Vigild,MartinE.III.Title.
TP248.3.W472007
660.6–dc22
2007014316
BritishLibraryCataloguinginPublicationData
AcataloguerecordforthisbookisavailablefromtheBritishLibrary
ISBN978-0-470-06154-1(HB)
ISBN978-0-470-06155-8(PB)
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Contents
Preface vii
Acknowledgments ix
Introduction xi
Lessons 1
Begin 3
1LookAround 5
2TeamUp 11
3GetaMethod 19
4AnalysetheSituation 27
Design 39
5FindNeeds 41
6SpecifytheProduct 55
7CreateConcepts 67
8SelectaConcept 81
9ProtecttheConcept 99
Develop 105
10FormulatetheProduct 107
11FlowsheettheProcess 117
12EstimatetheCost 127
13EquiptheProcess 139
14ScaleUp 149
Exploit 159
15OrganizetheMarket 161
16ForecastMoneyFlows 173
17LearntoSell 185
18PlanFutureProducts 193
Conclusion 205
continuedonthenextpage
v
Contents
Projects 207
P1UnderstandingProducts 209
P2FromNeedstoConcept 215
P3MakingaProduct 219
P4YourOwnProduct 223
Notes 227
N1ExperimentatHome 229
N2PlanYourProject 233
N3PresentYourResults 241
N4InterviewYourCustomer 249
Colloids 259
C1ProductStructure 261
C2Interfaces 269
C3Adsorption 277
C4Rheology 285
Index 295
vi
Preface
The twentieth century saw a huge expansion of the chemical industry–and of the career
possibilitiesforindustrialchemistsandchemicalengineers.Forexample,between1950and
1980the number ofcarsin manywesterncountries grew aboutone hundredtimes.Andso
didtheindustrydeliveringthefuels,lubricants,metals,polymersandpaintsrequired.Growth
ratesof20%peryearwerenotuncommon.Thisstoppedaround1980asmarketssaturated,
and since then development in the bulk chemical industries has slowed down markedly as
havethenumbersofyounggraduatesgettingemployedthere.
Nowadaysmany chemicalengineers are finding workin the developmentof newproducts.
Theyworkforamuchmorediversesetofindustries–inwhichchemistryisusuallyonlyone
ofthedisciplinesthatareimportant.Youmayfindtheseengineersinelectronics,inprinting,
in medical technology, in the food, car and cosmetic industries ... The skills required in
suchindustriesarequitedifferentfromthoseinthe(rathersheltered)bulkchemicalindustry.
Developmentismostlydoneinmultidisciplinaryandmultifunctionalteams.Youngengineers
have to learnto work together in projects with people who speakdifferent languages (both
literally and metaphorically). Speed and a sense of urgency are more important than in the
optimizing of bulk chemical processes. Team members are not only expected to be good
engineers,butalsotounderstandwhycost,marketingandsellingareimportant.
Inthisbookweintroducemajortechniquesusedindesigninganddeveloping,roughlyinthe
sequence in which they will be used. We show how techniques have been used (or could
havebeenused)inavarietyofproducts:alaundrydetergent,insulatedwindows,toothpaste,
anti-foulingpaint,aninsulininjector,apowdercoating,aboxofmatches,herbicidecapsules,
foamed snacks, a pharmaceutical tablet, Rockwool insulation, a ballpoint and a methanol
catalyst.Theauthorshavebeeninvolvedinthedevelopmentofseveraloftheseproducts.
One can only learn to design and develop a product by doing it–not by reading a book.
In our own courses about eighty percent of the time is devoted to project work–we give
someexamples.Thisishardonbothstudentsandonus,becausewehavetofollowwhatthe
studentsaredoingwithouttellingthemwhattodo.Weusethelessonsfortheothertwenty
percent:tointroducestudentstothetechniquesandtoprovideaframeworkfortheirprojects.
Wehopethatyouwilllikethem.
Groningen/Lyngby,January2007
HansWesselingh(JohannesinDenmark),
SørenKiilandMartinE.Vigild
vii
Acknowledgments
This book has a long history. It is the result of two threads: one starting in Delft (and later
Groningen)inTheNetherlands,andtheotherinLyngbyinDenmark.Around1980atDelft
University of Technology, the chemist H.C.A. van Beek† was having a hard time trying
to get people to accept that large changes were coming in the chemical industry, and that
theyshouldbelookingathigher-value(structured)products.Hemanagedtoconvinceafew
of his colleagues, among them J.A. Wesselingh (JAW), L.P.B.M. Janssen (LJ) and H. van
Bekkum. Together they put a curriculum together for students interested in what was then
called‘productengineering’.In1982JAWandLJstartedacoursewhichgraduallyevolved
into‘learnhowaproductworksbydoingexperimentsandsettingupyourowntheories’.It
wasverysuccessful.
In 1990 both LJ and JAW had changed universities. By coincidence they were working
togetherinthesmalldepartmentofchemicalengineeringofGroningenwheretheycontinued
their course, but otherwise were very busy with other things. In 1996 the board of the
university–alarmedbythefallingnumbersofstudentsinchemistryandchemicalengineer-
ing–askedJAWtolookatthepossibilityofsettingupastudyonproductengineering.This
was to be broader than engineering alone, and they suggestedto do it together with people
fromthegroupofindustrialpharmacy(N.W.FKossenandlaterH.W.Frijlink)andtoform
a co-operation with the technically oriented people from the large department of business
administration. The idea was supported by the deans of the Faculty of Sciences (P.C. van
derKruitandlaterD.A.Wiersma).JAWsetupanumberofprojectsinwhichteamsoftwo
tofourmasters’studentsworkedayearonthedevelopmentofsomeproduct,togetherwith
a local industry. The students were given a small budget and had to run their own project
organizationwith helpfrom industry anduniversity. This was allveryexciting, although it
didconflictwiththeusualwayofdoingthingsinuniversity.(Thetwobigproblemswerethat
theuniversitywasnotusedtogivingbudgetandprojectresponsibilitytostudents,andthat
developmentprojectsdonotprovidescientificresearchoutput.)JAWwasretiredin2002,but
hissuccessorA.A.BroekhuisandR.MVoncken†havecarriedontheidea.Thedepartment
hasahealthyinfluxofstudentsonceagain.
In Lyngby an initiative was started in the year 2000. The head of the chemical engineer-
ing department, K. Dam-Johansen, who had been working as a research manager in the
paint industry, realised that product development was missing in the chemical engineering
curriculum. He started several initiatives involving the young staff members S. Kiil (SK),
G.Kontogeorgis (GK), J. Abildskov (JA), M.E. Vigild (MEV) and T. Johannessen (TJ).
TheywerejoinedbyJAWwhospentlargepartsof2003and2004asavisitingprofessorin
Lyngby.
ix