Industrial Process Laboratory

Engr. Achilles Espaldon

Intro/ Orientation-Similar to Product development-to develop products, processes of producing-opportunity for us to develop and test our creativity and innovative potential.

-To have projects where we apply the product/ concept to the outside world. To make a difference, both in the technical and business aspect.

-Apply knowledge learned in chemistry, ChE205 (CPI) and using/ developing our creativity, imagination and leadership.- work in teams, innovate, interact, consult, -Timeline: Nov2010-March2011

Intro/ Orientation

-Traditional classroom activity:-Class lecture, learn the theories, do some calculations, memorize, take quizzes, take exams, get good grades

IP lab :-Learning by doing, mostly all lab work -Tangible results-oriented-we present them both during Eng’g. week for a poster presentation and to potential clients outside.

Intro/ Orientation

Our Direction/ Thrust – Where are we heading?

1. Provide interface of pharmaceutical and consumer product industries2. Use of organics/ fruit and plant extracts, going organics, deviation from synthetics ..3. Clean living, promote Health, Wellness and Fitness4. Develop ‘Blue Ocean’ products as compared to ‘Red Ocean’http://en.wikipedia.org/wiki/Blue_Ocean_Strategy

Course Requirements1. Project (duration: from Nov2010-Feb 2011) – 70%

- Develop a product, define the marketing strategy/ positioning

- Design the process of producing- Design the packaging, artwork

2. Documentation, Marketing, Presentations, (Feb – Mar 2011) – 20%1. Therefore, 1 and 2 is from CONCEPT TO

LAUNCH !2. One exam only: Final examination (10%) the rest

are just experiments, assignments, research work, hands-on lab work

3. Grading is by group: passing is 80%

Course Deliverables1. Project binder (hardcopy and soft copy)

Must consist of;A. Formulation and ProcessB. Raw material specifications and certificates of analysesC. Packaging design (art work) and material specificationsD. Test methods (in-vivo or in-vitro) or consumer studies/ tests

(very important for presentation to clients!)E. Marketing study, market research and strategy, brand

nameF. Literatures and referencesG. Final product prototype, poster for Engineering weekH. Suppliers and toll manufacturersI. Costing

2. Product Prototype and poster

What are we going to learn/do here?1. Principles of Product development, ins and outs2. Marketing and Positioning3. Prototyping, stability studies, quantitative &

qualitative tests4. Designing the process5. Designing the packaging

1ST half workload– Developing the Product

Project1.Develop a product assigned by me2.Define the process how to produce large-scale using unit operations, industries we have learned in CPI3.Feb 2010 showcase (Engineering week)

2nd half workload – Innovation Case Studies or a possible business presentation with a company

Purpose is for us to be aware of the significant innovations happened for the past few years and learn how we can adopt such attitude

What to do during work hours?-Bring a laptop, on-line all the time -Lab gown

Form a team of 5 (multi-disciplinary approach) , assign a team name:1.Team leader2.Technical specialist 1/ researcher3.Technical specialist 2/ researcher4.Artist, creative designer 5.Marketing specialist/ supply chain analyst/ purchasing

Products that we will make1. Detergent powder2. Toothpaste3. Beverage RTD for geriatrics4. Beverage RTD for young teens5. Skin whitener6. Skin moisturizer7. fast-melt tablets

Schedule2010November – lectures, conceptualization stage, idea generation, brainstorming, formulation workDecember – continuation of formulation, prototyping2011January – prototype development and testingFebruary – showcase, costing, written report compiled in a binderMarch – innovation case assignments, if successful BFAD registration

How to start?Starting point for product development is the market.-There should be a demand, otherwise the product won’t sell even if there is technical sophistication-Demand would come in segments, unmet customer needs

-i.e. a satisfied customer will not entertain a new product.

Steps/New Product development process

1. Choose a product/ market segment2. Research on trends, niches (SPT: segmentation, profiling,

targeting)3. Identify a winning concept4. Research on how to develop the product5. Do rough calculations, computations, design etc.6. Initial formulation. Order chemicals, buy competitor’s/

benchmark products, do lab work to test7. Make final formulation. Produce the prototype, find toll

manufacturers8. Make the poster.9. Do the costing10. Find a potential client for a possible business presentation or

innovation case studies

Basics of Market Segmentation and Positioning

SPT1.Segmentation2.Profiling3.Targeting

Segmentation-Markets are segmented according to needs, images and not by population or social status-Categories are the markets, within it are the brands and segments-Ex. Beverage market, Iced tea category

Iced Tea drinks

Others

Energy drinks

MilkFruit drinks

Beer, liquors

Iced Tea drinks

C2

Nestea iced tea

Segmentation-We have to identify an unmet need or unsatisfied niche/ segment which can be profiled after-So after defining segments, next do profiling.

Profiling

1. Age group- babies, toddlers, teens, adults, old people

2. Social status- poor, lower middle class, upper middle class, rich

3. Image- simple lifestyle, showbiz, sporty, nerds, outgoing, party animals

- this is where we quantify the market and the business potential

-here, we see now numbers

Targeting- We choose the market with the largest business potential, degree of the dissatisfaction and compared with our own resources, technology and capabilities and with time.

Product Concepts/ Image

1. Healthy lifestyle2. For Medicinal use3. Sports and fitness4. Mental agility5. Comfort living6. Practical living

Rationale for having a concept:-This is where consumers connect/ associate themselves with the product-To satisfy a costumer’s need-Activation for a possible purchase

BreakNext, project assignment..

What is a formulation?-Active ingredient-Diluents-Stability enhancers-pH adjusters-Preservatives-Processing aids-Flavors and fragrances-Etc.-(must consist of quantities or % per unit product, rationale or purpose, plus cost and stability data)

What is a process?-All the unit operations involved in producing the product from processing to packaging-Must consist of process variables (i.e. temperature, mixing time, melting temperature, speed, rates, batch sizes etc.)

Stability Data1. Chemical analyses (HPLC-if needed, pH, microbial tests etc.) to

ensurea. the active ingredient is presentb. the active ingredient is present after shelf-lifec. The product is safe to consumersd. The product is physically consistent with changing

environmental condition)e. the product is chemically ‘inert’ with the packaging

2. Physical tests to ensure performance of the product vs. competitor – research on Test methods..both in-vivo and in-vitro testsa. Cleaning actionb. Taste (must have consumer test data to prove)c. Efficacy (effective to treat a headache for example)

Next meeting.. Submission of proposal. All will be discussed in the lab

In powerpoint. 15 min. max for each group.

Please bring laptop and ready internet connection for easy search of information.

Stability StudiesNext topic..

Consumer testsNext topic..

Basic Test MethodsNext topic..