Twin Screw Compounding Fundamentals: Scale-up, the Bump in the Road Between Development and Commercialization

May 22

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There is always a rush of excitement when a chemist has a new product that passes the critical test or receives the first commercial order. The first thing the product manager asks is “at what rate can our commercial line (s) make this material?” The process engineer must start using the available data to generate estimates for conversion costs. Important information for accurately scaling up a process include, the extruder size used to prepare the lab samples, the maximum throughput rates tested on the extruder, the desired commercial throughput rates, and the importance of heat transfer on the commercial line. 

Primary Topics: 

  • Learn the basics of scale up calculations
  • How to take a process commercial with fewer headaches
  • Understand what controls a twin-screw process 

Christopher Zaleski, Process Engineer 

Christopher Zaleski is a Process Engineer for Coperion’s Compounding and Extrusion division. He is responsible for carrying out twin screw extrusion trials at the process lab in Sewell, NJ, as well as providing technical support for process development, new machine sales and existing customers. Chris holds a BS in Chemical Engineering from Rowan University.