© 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)

Thank you... For more information visit www.uk-cpi.com

Email: Twitter:

info@uk-cpi.com @ukCPI