Design of Experiments (DOE) for Product and Process Improvements: A Phenolic Syntan Case Study

Content: For sustainable developments the chemical industry is continuously looking for technical innovations with wide potential implications. The Design of Experiments (DOE) approach has been proven to be a powerful tool in determining the relationship between factors affecting certain output variables. This is done to establish a 'cause and effect' relationship and eventually realize output optimization. In order to evaluate whether DOE can be implemented for improving our products and processes, a case study, focusing on the synthesis and production of traditional phenolic syntans was carried out within our R&D department. Although we can influence properties by application, the effect a retanning agent has on leather originates to a large extent from the chemistry involved. To understand interactions and the possibilities of targeted improvements of the production process, a DOE factorial design approach was used to identify the control parameters and their interactions in our phenolic syntan recipes that influence the various properties and effects. Instead of trial-and-error or one-factor-at-a-time practices, DOE made it possible to limit the number of lab experiments to one third (1/3) of the amount needed for completing our study. As a result, a much deeper and more consistent understanding of the building blocks’ interactions and how these influence the chemical process of phenolic syntan synthesis has been gained. This includes the amount of different building blocks, their molar ratios as well as process conditions. Aiming at achieving optimal efficiency for various projects, right now we are looking at possibilities in implementing DOE within Smit & zoon. Take-Away: The Design of Experiments (DOE) approach is a powerful tool in realizing process and product improvements. DOE factorial design can be used to identify control parameters and their interactions in a wide reage of (industrial) applications. DOE has been proven to be efficient and effective in optimizing phenolic syntan recipes and production process

Design of Experiments (DOE) for Product and Process Improvements: A Phenolic Syntan Case Study

Content: For sustainable developments the chemical industry is continuously looking for technical innovations with wide potential implications. The Design of Experiments (DOE) approach has been proven to be a powerful tool in determining the relationship between factors affecting certain output variables. This is done to establish a 'cause and effect' relationship and eventually realize output optimization. In order to evaluate whether DOE can be implemented for improving our products and processes, a case study, focusing on the synthesis and production of traditional phenolic syntans was carried out within our R&D department. Although we can influence properties by application, the effect a retanning agent has on leather originates to a large extent from the chemistry involved. To understand interactions and the possibilities of targeted improvements of the production process, a DOE factorial design approach was used to identify the control parameters and their interactions in our phenolic syntan recipes that influence the various properties and effects. Instead of trial-and-error or one-factor-at-a-time practices, DOE made it possible to limit the number of lab experiments to one third (1/3) of the amount needed for completing our study. As a result, a much deeper and more consistent understanding of the building blocks’ interactions and how these influence the chemical process of phenolic syntan synthesis has been gained. This includes the amount of different building blocks, their molar ratios as well as process conditions. Aiming at achieving optimal efficiency for various projects, right now we are looking at possibilities in implementing DOE within Smit & zoon. Take-Away: The Design of Experiments (DOE) approach is a powerful tool in realizing process and product improvements. DOE factorial design can be used to identify control parameters and their interactions in a wide reage of (industrial) applications. DOE has been proven to be efficient and effective in optimizing phenolic syntan recipes and production process

Design of Experiments (DOE) for Product and Process Improvements: A Phenolic Syntan Case Study

Content: For sustainable developments the chemical industry is continuously looking for technical innovations with wide potential implications. The Design of Experiments (DOE) approach has been proven to be a powerful tool in determining the relationship between factors affecting certain output variables. This is done to establish a 'cause and effect' relationship and eventually realize output optimization. In order to evaluate whether DOE can be implemented for improving our products and processes, a case study, focusing on the synthesis and production of traditional phenolic syntans was carried out within our R&D department. Although we can influence properties by application, the effect a retanning agent has on leather originates to a large extent from the chemistry involved. To understand interactions and the possibilities of targeted improvements of the production process, a DOE factorial design approach was used to identify the control parameters and their interactions in our phenolic syntan recipes that influence the various properties and effects. Instead of trial-and-error or one-factor-at-a-time practices, DOE made it possible to limit the number of lab experiments to one third (1/3) of the amount needed for completing our study. As a result, a much deeper and more consistent understanding of the building blocks’ interactions and how these influence the chemical process of phenolic syntan synthesis has been gained. This includes the amount of different building blocks, their molar ratios as well as process conditions. Aiming at achieving optimal efficiency for various projects, right now we are looking at possibilities in implementing DOE within Smit & zoon. Take-Away: The Design of Experiments (DOE) approach is a powerful tool in realizing process and product improvements. DOE factorial design can be used to identify control parameters and their interactions in a wide reage of (industrial) applications. DOE has been proven to be efficient and effective in optimizing phenolic syntan recipes and production process