Process & Formulation Troubleshooting Consulting

This service focuses on identifying and resolving root causes of formulation and production issues through data-driven and engineering-based approaches. Technical consultants analyze process flow diagrams, conduct controlled experiments, and apply continuous improvement methodologies such as Six Sigma and Kaizen to optimize efficiency and product stability.

By combining analytical data with hands-on experience, the consulting process delivers targeted solutions that minimize waste, improve consistency, and enhance process robustness.

Consulting Stages:

• Comprehensive process assessment: On-site evaluation of production lines and quality data review.
• Controlled laboratory testing: Simulation of operational conditions (e.g., mixing time, temperature, shear rate).
• Root cause analysis: Identification of the underlying problem—such as formulation incompatibility, raw material variability, or equipment malfunction.
• Implementation & validation: Adjustment of formulation or process parameters, monitoring outcomes, and ensuring reproducibility.

Benefits & Opportunities:

• Higher productivity: Optimized formulations and processes increase yield and reduce operational costs.
• Access to technical expertise: Benefit from specialized know-how without major in-house R&D investment.
• Process reliability: Early detection and correction of technical issues prevent unexpected downtime and production loss.
• Sustainable operation: Reduced waste, lower energy consumption, and improved resource efficiency contribute to long-term sustainability.