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How can process innovation reduce the time to market for new products?

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In the competitive and dynamic world of chemical engineering, launching new products faster than your rivals can give you a significant edge in the market. But how can you reduce the time to market without compromising on quality, safety, and profitability? The answer lies in process innovation, the systematic and creative application of engineering principles and methods to improve the design, operation, and optimization of chemical processes. In this article, you will learn how process innovation can help you achieve four key benefits: faster prototyping, better scale-up, lower costs, and higher performance.

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1 Faster prototyping

One of the main challenges in developing new products is to test and validate your ideas in the lab before moving to the pilot or commercial scale. This can take a lot of time and resources, especially if you have to deal with complex reactions, separations, and formulations. Process innovation can help you speed up this stage by using tools such as computer-aided design (CAD), process simulation, and artificial intelligence (AI) to model, analyze, and optimize your process parameters and outcomes. These tools can help you reduce the number of experiments, identify the optimal operating conditions, and predict the potential risks and opportunities of your process.

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Martin Comer

NPI / NPD | Strategic Global Business Executive | Complex Problem Solver | Collaborative Innovator | Driver of Sustainable Growth |?Transforms Challenges into High-Growth Opportunities
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Faster prototyping happens when you have a clear set of requirements as to what you want the product to be. Follow this with a strong systems engineering approach to map out derived requirements to the appropriate levels. Utilize an agile approach to ensure that the prototype is heading on the right direction in real-time. Don't let the tools tell you the right direction, PDCA your way to success in delivering a fast qualitative prototype.

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Marco R M Barros

Eng produto JFAlmeida
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AI can be an essential tool for simulating processes in the product development phase, and thereby helping with their development and innovation.

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Mohammad Abrar

Mechanical Engineer | Plant Maintenance | Utility Management | Quality Assurance | Project Management | ISO & Six Sigma Certified
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AI can be used for faster prototyping and extensive use of 3D printing alongwith CAD can improve in prototype and then carrying the results in commercial production.

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2 Better scale-up

Another challenge in bringing new products to the market is to scale up your process from the lab to the plant without losing efficiency, quality, or safety. This can be tricky, as some phenomena that are negligible or manageable at the lab scale can become significant or problematic at the larger scale. For example, heat and mass transfer, mixing, and reaction kinetics can vary depending on the size and geometry of the equipment, the flow regime, and the operating conditions. Process innovation can help you overcome this challenge by using tools such as computational fluid dynamics (CFD), process intensification, and modular design to enhance the transport phenomena, reduce the equipment size and complexity, and facilitate the integration and flexibility of your process.

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Wen Cavalieri

Process Engineer
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Technology Transfer to save time and simplify the design Better scale up using simulation softwares Right equipment sizing and layout for your applications Lower cost Reduce transfer time

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3 Lower costs

A third challenge in launching new products is to reduce the costs of your process, both in terms of capital and operating expenses. This can be difficult, as you have to balance the trade-offs between the quality, yield, and profitability of your product. Process innovation can help you lower your costs by using tools such as life cycle analysis (LCA), process integration, and waste minimization to evaluate the environmental and economic impacts of your process, optimize the energy and material flows, and reduce the waste generation and emissions.

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Aditya Bansal

Process Engineer @ S&B | Oil & Gas | LNG | Petrochemicals | Hydrogen | Energy Transition
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Consider a scenario in the pharmaceutical industry where a company is developing a new drug. To reduce costs, they may invest in process innovation by implementing cutting-edge technologies such as continuous manufacturing. By utilizing techniques like process integration and waste minimization, they can optimize the production process, ensuring efficient use of resources while maintaining high-quality standards. For eg, they might employ advanced analytics to monitor and adjust process parameters in real-time, leading to better yield & reduced material wastage. This not only lowers operating expenses but also aligns with sustainability goals, enhancing the company's reputation and appeal to environmentally-conscious consumers and investors

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4 Higher performance

A final challenge in delivering new products is to ensure that they meet or exceed the expectations and needs of your customers and stakeholders. This can be demanding, as you have to deal with the changing market demands, regulatory standards, and competitive pressures. Process innovation can help you achieve higher performance by using tools such as quality by design (QbD), process control, and continuous improvement to incorporate the customer requirements and feedback into your process design, monitor and adjust the process variables and outputs, and implement the best practices and lessons learned.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Tom Coffman

Business Leader, Board Member, Board Advisor - Plastics & Packaging Professional
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Legacy development programs often fall back upon "linear" methodologies. Although such sequential regimen can showcase progress on top of existing infrastructure (e.g. installed capital/machinery, existing processes), it will also only resolve to a "tweak" of the current industry. There is a place for such innovation, but "step change" improvements in products and processes frequently evolve from asymmetric thinking, new and not nuanced shifts in "the way its always been". Take what is good and make it better; but "change" may often require "creation". Define the "box", and optimize the "box", but don't be afraid to step outside and look for something different.

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How can process innovation reduce the time to market for new products?

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3

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1 Faster prototyping

2 Better scale-up

3 Lower costs

4 Higher performance

5 Here’s what else to consider

Chemical Engineering

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