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It is no longer necessary to use a jacketed laboratory reactor for precise temperature control.
When scaling up the experiment, the reactor is not the only way to get good correlation and avoid some problems that may be caused by small-scale heating plates (or similar heating-only devices).
Radleys, a chemical equipment manufacturer, has developed the Mya 4 reaction station, which provides precise temperature control in four independent zones in a benchtop unit with a volume of 0.5-200 ml.
Image source: Johnson Matthey
The development chemists of Johnson Matthey (JM) discovered subtle but statistically significant differences in the impurity profiles when they were studying the key process parameters for the manufacture of active pharmaceutical ingredients.
Their research showed that the problem was caused by the parallel reactors they used, which resulted in a lack of consistency in the temperature profile.
Dr. Timothy Davies, a senior development chemist at JM, commented, “Without an accurate temperature, successful design of experiments (DoE) exercises cannot be performed.”
Dr. Timothy Davies, Johnson Matthey Senior Development Chemist
In eight identical experiments, the development team’s previous settings would show that the reaction temperature varied between 51.2 – 55.3 °C, although they always set the temperature to 55.0 °C. This results in an undesirable impurity content of 1.98 – 3.23% at the end of the reaction.
Using Mya 4 for the same experiment, they were able to accurately control the reaction temperature at 55 ⁰C in four repetitions. This results in a more consistent and lower impurity content distribution of 1.84 ± 0.07%.
It turns out that it is difficult to quantify the influence of other variables (such as reagent stoichiometry and stirrer speed), because temperature is the most important variable that affects the distribution of impurities in JM's experimental research.
Dr. Davies added: “The temperature control accuracy provided by Mya 4 is critical to understanding the key process parameters of temperature-sensitive experiments. It allows us to improve our understanding of current manufacturing processes.”
Thanks to the installation of the Mya 4 reaction station, JM's development team achieved meaningful, reliable and repeatable results through consistent and accurate control.
The equipment upgrade also allows JM development chemists to complete tasks that were previously impossible, such as conducting DoE exercises on a smaller scale.
Determining the key parameters to be improved on a small scale will have a significant impact on the manufacturing scale
Dr. Timothy Davies, Johnson Matthey Senior Development Chemist
Whether it is studying existing manufacturing processes in the laboratory to better understand key reaction parameters, or process chemists are studying small-scale processes that will be applied to manufacturing scale, the link between process development and manufacturing is crucial.
Achieving similar conditions on a small and large scale is crucial.
Dr. Davies pointed out, “If we can obtain better experimental data and determine a key parameter to make small-scale improvements—for example, better temperature control—this will have an impact on the scale of manufacturing—for example, a 5% increase in production. It also helps to justify the capital expenditure of production facilities."
The laboratory of Dr. Patrick Gilbert, Technical Director of Purolite Life Sciences, focuses on the functionalization of resins and biomolecules; these resins are highly sensitive to temperature fluctuations.
To deal with these resins, Dr. Gilbert's team needed a more reliable form of temperature control to replace water/oil baths and electric furnaces. The same group is accustomed to using jacketed laboratory reactors and obtaining scalable, repeatable and reliable results.
Mya 4 satisfies the need for a multi-purpose small reactor system that is not over-specified. The fact that the device is versatile is a powerful advantage. In previous systems I have looked at, the flask size was limited to one or two options. I would like it two years ago, so I can use it as the workhorse of most projects.
Dr. Patrick Gilbert, Technical Director of Purolite
In just a few weeks after installation, Mya 4 had already had a huge impact in Purolite's laboratory. Mya 4 is now used in research and development every day, especially because it can handle the exothermic process, which is a feature of several key projects.
Another application currently using Mya 4 is to immobilize proteins on the resin surface at 30 °C.
Prior to Mya 4, this proved to be a difficult application (especially when compared to round bottom flasks in water/oil) because of its limited temperature window to avoid denaturation and close to ambient temperature.
Now it is possible to directly expand the scale of the experiment to the pilot scale, and at the same time it can be carried out in small batches, which means that Purolite can reduce waste and reduce costs.
Chemical scientists around the world use Mya 4 reaction stations in a wide range of applications.
An American cannabinoid research company's research and development senior process development chemist commented: "We have done a lot of reaction optimization work (different catalyst loads, different temperatures, etc.), and recently had to perform crystallization optimization, which requires careful control of the cooling slope— —All this is easy for Mya 4 and makes our research progress faster."
Mya 4 helps many chemists who need precise control of working volumes up to 200 ml through the precise temperature control of the jacketed laboratory reactor, but on a smaller scale.
Chemists all over the world are using Mya 4 to obtain scalable, repeatable, and reliable results. Radleys provides online and face-to-face demonstrations of this innovative laboratory equipment.
This allows end users to decide for themselves how to improve their work, reduce costs and waste, and simplify their operations.
“Making chemists’ lives in the laboratory easier is our main goal at Radleys, and Mya 4 is doing this,” said Dr. Keren Abecassis, Radleys’ Mya 4 product manager. He is very pleased to see the positive impact of the reaction station. In the customer’s laboratory.
Image source: Radlis
From R&D chemists in the pharmaceutical industry to chemists developing new materials for the energy sector, Mya 4 is changing their jobs when accurate temperature control is essential. In an era of increasing productivity and streamlining processes through automation, Mya 4 is playing its role, providing 24/7 unattended chemistry and precise temperature control options. I am very happy how Mya 4 has contributed to the success of my chemist colleagues and excited about the future of the product.
Dr. Keren Abecassis, Mya 4 Product Manager, Radleys
Mya 4 is a four-zone reaction station that provides precise heating, active cooling, software control, and data logging for 24/7 unattended chemistry.
This innovative reaction station offers great flexibility: magnetic or top stirring options, multiple container options from 2 ml to 400 ml, and independent control of four zones with a temperature range of -30 °C to 180 °C .
The scope of application of Mya 4 includes:
This information is derived from materials provided by Radleys and has been reviewed and adapted.
For more information on this source, please visit Radleys.
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Radlis. (September 9, 2021). Radleys reaction stations enable chemists to better manage small-scale experiments through accurate temperature control. AZoM. Retrieved from https://www.azom.com/article.aspx?ArticleID=20449 on November 12, 2021.
Radlis. "Radleys' reaction station enables chemists to better manage small-scale experiments through accurate temperature control." AZoM. November 12, 2021. <https://www.azom.com/article.aspx?ArticleID=20449>.
Radlis. "Radleys' reaction station enables chemists to better manage small-scale experiments through accurate temperature control." AZoM. https://www.azom.com/article.aspx?ArticleID=20449. (Accessed on November 12, 2021).
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