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Synthetic Pharmaceutical Example on Throughput Analysis and Debottlenecking Theory

INTELLIGEN, INC. Synthetic Pharmaceutical Example on Throughput Analysis and Debottlenecking Theory. Pilot Plant Production. =. 55.7 kg/batch. Large Scale Manufacturing. =. 25,000 kg/yr. INTELLIGEN, INC. Overall Chemistry - Production Requirement.

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Synthetic Pharmaceutical Example on Throughput Analysis and Debottlenecking Theory

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  1. INTELLIGEN, INC. Synthetic Pharmaceutical Example on Throughput Analysis and Debottlenecking Theory

  2. Pilot Plant Production = 55.7 kg/batch Large Scale Manufacturing = 25,000 kg/yr INTELLIGEN, INC. Overall Chemistry - Production Requirement Quinaldine + Hydroquinone ==> Product Annual Operating Time £ (330 days/yr)(3 shifts/day)(8 h/shift)

  3. INTELLIGEN, INC. Operations Gantt Chart - Base Case

  4. INTELLIGEN, INC. Scenario 1 Equipment Available Two 1,000 gal reactors (R-101 and R-102) One 4 m2 Nutsche filter One 10 m2 Tray Dryer (1 kg/h drying capacity) Pilot Scale Batch Size Produced in Large Scale Equipment

  5. INTELLIGEN, INC. Scenario 1 (continued) Batch throughput Number of Batches per Year Annual Throughput Scheduling (Time) Bottleneck Cons. Batch Throughput Bottleneck 55.7 kg 138 7,670 kg R-102 (56 h cycle) R-102 (32.5% Cap. Util. in P-11)

  6. INTELLIGEN, INC. Scenario 1 (continued) Action 3 fold batch throughput scale up New Results Batch throughput Number of Batches per Year Annual Throughput Scheduling (Time) Bottleneck Cons. Batch Throughput Bottleneck 167 kg 115 (initial 138) 19,205 kg < 25,000 kg R-102 (67 h cycle) R-102 (97.5% Cap. Util. in P-11)

  7. INTELLIGEN, INC. Scenario 2 Equipment Available Three 1,000 gal reactors (R-101, R-102, R-103) One 4 m2 Nutsche filter One 10 m2 Tray Dryer (1 kg/h drying capacity)

  8. INTELLIGEN, INC. Scenario 2 (continued) Batch throughput Number of Batches per Year Annual Throughput Scheduling (Time) Bottleneck Cons. Batch Throughput Bottleneck 167 kg 135 (115 => 135) 22,545 kg < 25,000 kg NFD-101 (57.3 h cycle) R-103 (97.5% Cap. Util. in P-11)

  9. INTELLIGEN, INC. Scenario 3 Equipment Available Three 1,000 gal reactors (R-101, R-102, R-103) Two 4 m2 Nutsche filters One 10 m2 Tray Dryer (1 kg/h drying capacity)

  10. INTELLIGEN, INC. Scenario 3 (continued) Batch throughput Number of Batches per Year Annual Throughput Scheduling (Time) Bottleneck Cons. Batch Throughput Bottleneck 167 kg 142 (115 => 135=>142) 23,714 kg < 25,000 kg R-102 (54.4 h cycle) R-103 (97.5% Cap. Util. in P-11)

  11. INTELLIGEN, INC. Scenario 3 (continued) R-103 Equip. Cap. Util.: High in P-11 and Low in P-5 Action 1) P-11 increase cycles/batch from 1 to 2 2) Increase batch size by 47% (limited by P-9 \ R-102)

  12. INTELLIGEN, INC. Scenario 4 Batch throughput Number of Batches per Year Annual Throughput Scheduling (Time) Bottleneck Cons. Batch Throughput Bottleneck 245.7 kg (55.7 => 167=> 245.7) 110 (115 => 135=>142=>110) 27,027 kg> 25,000 kg R-103 (70 h cycle) R-102 (99.9% Cap. Util. in P-9)

  13. INTELLIGEN, INC. Comparison Scenario Number Reactor Vessels Nutsche Filters Batches per Year Batch Throughput Annual Throughput 1 2 1 115 56 kg 19,200kg 2 3 1 135 167 kg 22,500kg 3 3 2 142 167 kg 23,700kg 4 3 2 110 246 kg 27,000kg

  14. INTELLIGEN, INC. Labor Demand as a Function of Time

  15. INTELLIGEN, INC. Cost Analysis

  16. Equipment Cost $2.4 M Total Investment $16.3 M Operating Cost $7.6 M/yr Unit Cost $283/kg INTELLIGEN, INC. Economic Evaluation Results Waste Treatment/Disposal 10% Laboratory/QC/QA Raw Materials 4% 22% Equipment-Dependent Labor-Dependent 40% 24% Production Rate 27,000 kg/yr Batches per Year 110 Equipment Three 1,000 gal reactors, Two 4 m2 Nutsche filters, One 10 m2 tray dryer.

  17. INTELLIGEN, INC. Raw Materials Cost Breakdown

  18. Product = 2 % Raw Materials INTELLIGEN, INC. Environmental Impact

  19. INTELLIGEN, INC. Summary • Facilitate Process Development • Improve Team Communication • Reduce Capital and Operating Cost • Debottleneck Manufacturing Facilities

  20. Summary • Plant Throughput Depends on Equipment Capacity, Time Utilization and Resource Capacity (instantaneous and average). • Throughput Analysis Tools Can Play a Role in: 1) Designing New Balanced Plants, 2) Sizing Utilities of Batch Plants, 3) Retrofitting Existing Facilities and 4) Improving Utilization of Existing Equipment.

  21. Fully Functional Demo of SuperPro Available on Website www.intelligen.com

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