Solvent Separation From Silicone Resin: A Case Study in Process Route Selection

Amid business pressure for rapid commercialization, route selection is easily overlooked to focus ever limited resources on fast implementation. However, this tendency can lead to expensive, inefficient, and unreliable processes. Even brief comparison of multiple process routes can yield a more efficient, sustainable, and robust process for decades of successful manufacturing.

This poster examines a case study in route selection around a silicone resin-solvent separation. The highly viscous nature of the resinous material challenged traditional separation techniques. First, the team proposed pre-dilution with low viscosity silicone fluids to enable consideration of multiple separation techniques. Next, an alternative separation technique was recommended to improve manufacturing capability, conversion cost, and quality consistency. Finally, a mid-process, partial dilution was planned to create a leverageable intermediate, reduce contamination risk, and maximize bulk packaging flexibility. 

Early-stage consideration of safety, sustainability, feasibility, cost, supply chain, timing, and risks ultimately led to implementation of a robust, and profitable process. Furthermore, transitioning from the presumed process route to an alternate route reduced manufacturing risk, process waste, and even time to launch by avoiding failed scale-up attempts with an incapable process. Overall, this process development example demonstrates the importance of balancing adequate process route consideration with swift implementation for the greatest business impact.