Industrial Product Design of Solids and Liquids
A Practical Guide

Preface

CHEMICAL PRODUCT DESIGN -
A NEW APPROACH IN PRODUCT AND PROCESS DEVELOPMENT
Definitions
Customer Involvement
Specifications
Tasks of Development Team
Steering of Projects
Learnings

DIVERSITY OF PRODUCT DESIGN
General Remarks
Customizable Developments
Foodstuffs
Chemicals
Cosmetics and Pharmaceuticals
Polymers and Plastics
Ceramic Industry
Packaging
Brand
Learnings

GENERATION AND ASSESSMENT OF IDEAS FOR NOVEL PRODUCTS
Innovation
Implementation of a Product Idea
Project Success (Some Personal Reflections on the People Involved)
Generation of Innovations
Evaluation of Product Ideas
Learnings

COMPRESSED DEVELOPMENT AND IMPLEMENTATION OF INNOVATIONS
Preliminary Remarks
Reasons for an Accelerated Product Development
Risks
Barriers in Development Projects
History
Compressed Project Processing
Project Leadership
Teamwork in Projects
Conditions for Success of Compressed Project Work
Design of Production Plant
Biotechnology
Maximum Speed-to-Market (Examples)
Relationship between Compressed Development and Product Design
Outlook
Learnings

PRODUCT DESIGN OF PARTICLES
Dry Agglomeration Processes: Pelleting and Tableting
Wet Agglomeration Processes: Granulation
Learnings

PRODUCT DESIGN OF PARTICLES BY COATINGS
Processes for Setting the Product Design of Particles
Opportunities for Influencing the Particle Design
Tasks of Coatings
Basic Variants of Coating
Coating Technologies
Learnings

PRODUCT DESIGN OUT OF DISPERSE AND CONTINUOUS PHASES BY CRUSHING
Breaking Up of Materials
Importance of Crushing Processes
Particle Properties by Breaking Up
Variants of Crushing
Processes for Crushing of Materials
Energy Requirements
Determination of Product Design via Specifications
Design of Products by Breaking Up Processes
Product Design Out of Multistep Processes (Examples)
Consequences
Learnings

PRODUCT DESIGN OUT OF CONTINUOUS PHASES BY SPRAY DRYING AND CRYSTALLIZATION
Importance of Spray Drying
Basics of Atomization and Drying
Spray Drying Plants and Plant Safety
Improved Capacity and Energy Consumption
Influencing the Product Design
Scale-Up of Spray Dryers
Exhausted Air and Waste Water
Spray Agglomeration
Crystallization /
Precipitation
Learnings

MANUFACTURING OF APPLICATION-RELATED DESIGNED PLASTIC PRODUCTS
Polymers
Importance of Plastics
Task
Polymer Design for Plastics
Polymers in Detergent Formulations
Plastics in Detergent Industry
Shape and Function
Learnings

PRODUCTION OF TAILOR-MADE ENZYMES FOR DETERGENTS
Product Design in Biotechnology
History
Enzymes
Enzymes in Detergents
Industrial Manufacture of Proteases
Workplace Safety
Product Design of Enzymes
Learnings

DESIGN OF SOLID LAUNDRY DETERGENTS ACCORDING TO CONSUMER REQUIREMENTS
Market Products in Germany
Identification and Consideration of Customer Needs
History of Laundry Washing
Washing Process
Recipe
Design of Finished Products
Manufacturing Processes
Novel Manufacturing Method for Granules
Economic Considerations
Outlook
Learnings

PRODUCT DESIGN OF LIQUIDS
Introduction
Water-Based Liquids
Water-Insoluble Liquids (Example: Perfume Oils)
Learnings

DESIGN OF SKIN CARE PRODUCTS
History of Cosmetics
Regulations of Cosmetics Products
Product Design
Skin Care
Emulsions
Structure of Skin Creams
Essential Active Substances from Medical Point of View
Penetration into the Skin
Targeted Product Design in the Course of Development
Production of Skin Care Products
Bottles and Prices for Cosmetic Creams
Design of all Elements
Learnings

INFLUENCING THE PRODUCT DESIGN BY CHEMICAL REACTIONS AND MANUFACTURING PROCESS
General Remarks
Elements of the Manufacturing Process
Raw Materials and Synthesis Routes
Chemical Reactor and Reaction Sequence
Entire Procedure
Choice of Machines and Apparatuses
Operation Conditions
Drying Gas
Learnings

DESIGN OF DISPERSE SOLIDS BY CHEMICAL REACTIONS
Importance of Solid-State Reactions
Theoretical Bases
Modeling of Isothermal Solid-State Reactions
Modeling of "Adiabatic" Solid Reactions
Reactions of Disperse Particles in the Industry
Formation of Products
Etherification of Cellulose
Dry Neutralization
Building Materials
Hints for Practice
Learnings

MATERIALS FOR THE MACHINERY
Relationship between Material and Product Design
Choice of Material
Stainless Steel
Nonferrous (NF) Metals and Alloys
Inorganic Nonmetallic Materials
Plastics
Learnings

PRINCIPLES OF PRODUCT DESGIN
Characteristic Features
Targeted Production of Particles and Fluids from Different Raw Materials
Learnings

Index

Dr. Wilfried Rähse has been Partner of a start-up (ATS License GmbH) for several years and is responsible for the scientific development of formulations and production processes of novel cosmeceuticals. Previously, Dr. Raehse worked at Henkel AG & Co. KGaA as director in the field of process development. The focus of his activities for washing, cleaning and skin care products were product design, the development of innovative processes and products for the future and the downstream processing of enzymes. His ideas and works led to large production facilities, such as the processing of enzymes, the steam drying in a spray tower and the Megaperls®, a washing powder in form of spheres. Dr. Raehse studied at the Technical University of Berlin chemistry and chemical engineering. He completed his PhD under the supervision of Prof. Dr. Dr. H. Koelbel in 1976. After a period as an assistant (1971 to 1977) at the College followed a 30-year industry activity at HENKEL in process development, but also in the production and in the environmental technology. Dr. Raehse has written many articles and a book (2007) on product design. He holds academic lectures and lecture at universities and at conferences about the optimization of products and processes, including chemical and engineering aspects