Design for Formulation – Products and Processes

Two-day Training Workshop: 19th-20th September 2017

Jury’s Inn Hotel, East Midlands Airport, UK

Note: This event has now taken place. Please contact info@iformulate.biz if you are interested in accessing course materials or future training on this topic.

Proper design of formulated products – and of the processes used to make them – brings significant benefits to companies. Good design can:

• Help to get your product to market more quickly;
• Lead to more robust products and processes – reducing the risk of rejects and complaints;
• Reduce the requirement and risk for capital expenditure at the manufacturing stage;
• Help you achieve successful scale up from lab to plant;
• Reduce your costs in manufacturing and product/process development;
• Improve relationships with suppliers and customer;
• Help you understand your formulation better – and help you design next generation products more effectively.

To help you with design for formulation, we’ve put together this training workshop.

Who Should Attend?

• Those in a technical function (e.g. R&D, Quality, Process Development, Manufacturing) in any formulating industry (e.g. pharmaceuticals, home/personal care, agrochemicals, paints, inks, adhesives, lubricants, food etc);
• Others involved in the new product development process (e.g. purchasing, marketing) who may become involved in product or process design for formulated products.

How Will You Benefit?

You will benefit from attending “Design for Formulation” by:

• Understanding the linkage between the business functions involved in product and process design;
• Being able to devise and implement a product design strategy before you go into the lab;
• Gaining a basic understanding of the principles and practice of experimental design (DoE);
• Gaining insights into the key considerations on taking a product or process into pilot scale;
• Learning how to plan to ensure a process is robust and suitable for commercial manufacture;
• Ensuring your product and process are future-proof, i.e. capable of being adapted to meet future requirements.

Download “Design for Formulation 2017” Course Flyer

You can also take a look at the recording of our short webinar from 2015 in which Ian Jolliffe introduces “Design for Formulation“.

Workshop Programme:

Day 1: Principles, Laboratory and Pilot Scale

9.00 – 16.30

• Formulation Design: What’s in it for you and your business? Dr David Calvert, Director, iFormulate Ltd
  • What are the objectives and benefits of formulation design?
  • Terminology and process flows
  • Principles of process development and technology transfer
  • Co-operation with other key business functions
• Getting Started: Before you go into the lab. Dr Ian Jolliffe, Associate Partner, iFormulate Ltd
  • Reviewing prior knowledge
  • Preformulation
  • Risk assessments
  • Development strategy – what, how and why?
• Design of Experiments (DoE). Dr Paul Murray – Paul Murray Catalysis Consulting
  • Principles of DoE
  • Benefits of using DoE, and some possible pitfalls
  • Maximising knowledge to help expedite the development programme
• Application of Design of Experiments. Dr Gilda Gasparini – Lucideon Limited
  • Practical applications of DoE for multi-factor processes.
  • Three case studies showing three different approaches to DoE:
  • 1. DoE to find the best synthesis for a defined target performance, including an overview of software: Design Expert by StatEase
  • 2. An alternative approach using historical data and how to handle a large volume of existing results
  • 3. Use of DoE to perform early scale up study and verify the robustness of the process ready for transferring to pilot plant.

• Team Exercise. Dr Ian Jolliffe and Dr David Calvert
  • Risk assessment
  • Experimental development strategy
  • Experimental plan
• Reality Dawns: Development to pilot scale. Dr Ian Jolliffe
  • Process design and process stretch
  • Preliminary process qualification and test methods

Day 2: Scale-up, Manufacture and Realising the Benefits

9.00 – 16.30

• Reality Dawns, Scale Up, Risk Assessments Exercise. Dr Ian Jolliffe, Associate Partner, iFormulate Ltd
  • Refinement of risk assessment. Residual risks
  • Review of challenges from development and scale-up
  • Planning for industrial scale trials
• Industry Case Study – Pilot Trials and Scale-up. Prof Phil-Threlfall-Holmes, TH Collaborative Innovation
  • Awareness of the potential pitfalls in scale-up can help you design an effective pilot programme, to mitigate the risk of expensive delays and failures when moving from lab to manufacturing scale.
  • The session will be illustrating by examples from industrial practice when things didn’t go quite to plan.
• Processes and Control Strategies for Manufacturing Productivity. David Hood, The Excellence Partnership
  • Today, all organisations are using lean, six sigma, operational excellence or some other form of continuous improvement (CI) methodology.
  • When developing new products (NPD), we need to understand both the expectations of our production units in relation to CI, and how we can apply CI to the NPD process
  • David Hood – an renowned authority on CI – working for The Excellence Partnership Ltd, will help develop our knowledge of what’s required to make our NPD process effective.
• Exploiting the Knowledge: Dr Ian Jolliffe
  • Future benefits
  • Robustness, high process capability and future proofing
  • Flexibility – equipment and materials
  • Regulatory agility

Venue

Design for Formulation will be held at the Jury’s Inn Hotel, East Midlands Airport, UK. The location is convenient for road (M1), mainline rail (East Midlands Parkway) and air (European and UK) connections. Further details on the venue and travel connections can be found here.

Pricing

Two-day training workshop – standard rate: £750+VAT per person

Registration and Further Information

Attendees will receive copies of all workshop materials on a USB memory stick. Lunch and refreshments will be provided for attendees but accommodation and other meals are not included.

Terms and conditions can be found here. If you have any further queries you please e-mail us at info@iformulate.biz.