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© 2015 Centre for Process Innovation Limited. All Rights Reserved.
Innovation in Collaboration: an Intro to the NFC
National Formulation Centre FSTG Encapsulation Event, Edinburgh, 10th June 2016
Dr. Graeme Cruickshank Director, Formulation – CPI
Who are CPI?
CPI is a UK technology innovation centre and the Process element of the Government’s
High Value Manufacturing Catapult.
We use applied knowledge in science and engineering combined with state of the art facilities
to enable our clients to develop, prove, prototype and scale-up the next generation of
products and processes.
Industrial Biotechnology & Biorefining Formulation National Printable
Electronics Centre National Biologics
Manufacturing Centre
De-risking Translation from Invention to Invoices • We support companies crossing the gap between research and commercialisation.
Investor Ready
Innovation Ready
TRL 1-3 Research & Invention Mainly Public
TRL 4-7 Innovation Public/Private Collaboration
TRL 8 & 9 Commercial
Market Private
Formulation (Integrate to Deliver Surprising Benefits)
Formulation, the creation of multi-component, often multi-phase products, is an enabling capability
Creating value through intricate microstructures and powerful ingredient synergies
Underpins many sectors in our economy and high-value manufacturing industries globally.
The formulated products market in the UK is worth around £180 billion pa with a potential for companies in emerging overseas markets of around £1,000 billion pa
The National Formulation Centre - Overview
Create value for UK-based companies through Formulation science by enabling; Bigger, Cheaper or Faster innovation.
Productivity from value-creating strategic alliances with industry and the wider UK formulation eco-system (inc SME/supply chain and Knowledge Base (Academic) partners)
Create and use an industry-led portfolio of advanced capabilities. Sweat the UK assets by best harnessing current capabilities (in academia or elsewhere) and then plugging any critical gaps identified by developing “open access capability”
Sustainability from enduring access and application of advanced capabilities
FORMULATION CHALLENGE
Underpinning Technologies
Colloid Science Polymer Science Metrology Manufacturability
Handling Solids/liquids Assess Properties / Test Applications Scale Up
Analytical Sciences
Learn Thoroughly High Throughput Tools and Digital Knowledge
Management Systems
Model Move beyond simple models to more integrated
systems
Predictive Design Ultimate goal for all Formulators
Move Formulation from Art to Science (Predictive Design/ Radical Effects / Manufacturability)
Move from Art to Science
• Productivity and Simplification for UK-Based R&D and Manufacturing by development
and expansion of best Modelling practice as we move to Predictive Design
Structure – Activating the Innovation Eco-system Frames capability challenges (what’s needed)
Co-develops associated technologies(what’s possible)
Provides scientific understanding and enabling capabilities (possibility)
Lens for UK Formulation Innovation Eco-system (Clarity and Focus)
SMEs
HVM Catapult, CPI National
Formulation Centre
Home and Personal Care
Food and Drink
Paints and Coatings
Oil and Gas
Industrial Products
Pharma and Healthcare
Uni X Uni Y
Uni Z Uni A
Uni B
Uni C
Catapults
Research Centres
Collaboration vehicles
Capability Themes to Work Against
Big Data Innovation Enabler Critical foundational component for knowledge management and problem solving
Faster, more reliable approaches to get to ideal formulation design
Faster Innovation
Predictive Designs
Unexpected synergistic effects to deliver bigger/disruptive benefits
Bigger Innovation
Radical Effects
Optimised, reliable system to guarantee ideal formulated product delivery
Process Innovation
Manufacturability
NFC Creating Unique, Vital and Sustainable Capability
Big Data
Predictive Design
Radical Effects
Private Application of Capability Refining Capability using CRD Build Open Access Capability
1.1. Digital infrastructure
Partner X -
2.1 HT physical mapping platform
(solids)
2.2 Granule solubility prediction toolkit
1.3 Analytics to extract value from
existing data
3.1. New delivery systems
Investment Key
Industry Partner X cash in-kind
Other companies cash in-kind
NFC Grant
CR&D Grants
Manf.
National Formulation Centre Project Funnel – June 16
Big Data
Predictive Design
Manufacturability
Complex Fluid Stability & Rheology
Liquid stability
prediction rig
Lead: P&G/BP
Big Data (Integrated Knowledge)
Flexible platform for
data-rich ingredient selection
Lead: CPI, Unilever
Complex Liquid formulation Scale-up
i) Sensor demo loop (scale-up) ii) suite of
sensors
Lead: CPI
Particle models for industry
Embeds academic models in
industry
Lead: Pfizer
AZ/JM
Advanced Rheology toolkit
Non-contact
Rheology
Lead: Sun Chemical
Complex Liquid Formulations Scalability Understanding
Current status
• Foundation platform ordered as NO facility in UK to learn across 10Ls scale.
• Interim location (Birmingham Uni)
• NFC “Cleaning in process manufacturing” study to inform follow-on project - focussing innovation needs - quantifying cross-sector value
• Liquids Understanding Research Infrastructure open Q4 2016
1000 L 100 L
10 L
1 L
Particle sizing
Crystallite size / shape by FBRM
Viscosity
Democratising High Throughput Experimentation (efficiency in R&D) HTE platform with Solids & Liquids Handling vital core learning capability for all. Access for broader user base (SMEs etc.) •High flexibility with range of online & offline screens •Immediate use in:
•Validation datasets in support of NFC portfolio projects •Private funded assessments
•Allows sharing of Development s & Capacity with key partners i.e. MIF
•System procured, will be commissioned Q4 2016
Add solids, liquids, highly viscous materials to mg resolution while formulation is being processed Integrated and automated stirring, shaking, at controlled temperature, pressure. Real-time control of formulation parameters including Temp, shear rate and viscosity, scraping speed, pH
Liquids Highly Viscous Liquids Powders
Viscometry &
Rheology Particle Sizing NIR Imaging Stability
Integrated screens complemented by separate conventional lab capability
Complex Fluid Stability & Rheology Assessment Tool
Rheology, microstructure phase behaviour
T-control
Microflow processing and stability mapping
flow-control
T
Variable flow type and magnitude
Spatio-temporal rheology Formulation stability and fluctuations
Online metrology
(Big) data correlation with system and process parameters
Current status
• Rapid/Resource Efficient assessment of liquid product stability and failure predictions is a huge challenge today with no efficient options. Hence developing a unique capability.
• Technical plan being refined ensuring optimal value and impact for industry .
• Associate Partners to ensure future-proofing for cross-sector base
• Finalising contracts (target end June)
• Target start Q3 2016.
Implementation of Particle Models for Industry • Currently major capability gap to transfer models from Academia to Industry.
•Methodology and framework for translating models to industry • Wet granulation case study which will fit as a tool within CPI- Chariot granules facility
• Methodology /best practice guide and support network can be applied to other manufacturing processes
- Driving step-change modelling adoption - Complement commercial vendors - Creating UK hub for model commercialisation
and in-slico development
• Pic
Big Data - Integrated Knowledge System for Formulation
Current Status • This enables moving from art to
science requires faster access to integrated knowledge to guide future product development ,which is NOT available to industry today.
- Building on £1.5m IUK demo project
• NFC seeking additional end-user partners
• NFC working in partnership with
Digital Catapult
• Q3 2016 – target start
Integration
Interface Repository Services
surfactants
Repository Services
perfumes
Search Tools Models Curation
Tools
Bio based Sustainable Feedstocks
simple but scalable transformation
processes Generate test
Libraries
Testing Functional Properties & build
models
Repository Services
Models
Core Module
Connect to External Company data
Repository Services
incipients
NFC Digital Infrastructure
Formulation Lighthouse Vision 2030
Current Art of Formulated Products
More robust understanding of complex systems to enable model development • Solids • Liquids
Predictive Design from Models of evolving systems • Innovation efficiency • Productivity • R&D Simplification
Develop Truly delightful products in function and design (STEM to STEAM)
Autonomous learning with systems IoT enabled to formulate against real need/conditions
•Productivity and Simplification in Innovation from Predictive Design. •Ultimately created autonomously, from self-learning systems (IoT connected)