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Product development is not a single process. Good products are the result of careful market analysis, well designed experimental trials and a dedicated team of experts armed with the right tools. This is where The Unscrambler® family of products is unrivalled in completeness and applicability.
Whether you are in the food, chemical, pharmaceutical, paper and pulp or energy sectors, there is an Unscrambler based product to suit your needs. Some industry specific product development applications are provided in the following sections.
Keeping ahead of the competition is a key motivational driver in the pharmaceutical and biopharmaceutical sectors . Whether you are an innovator looking to develop the next blockbuster drug and having a future pipeline of drugs , or a generics manufacturer looking to re-engineer an off patent drug in the shortest possible time, The Unscrambler® family of products has the right application for the various stages of product development. A typical new development may include the following stages and use corresponding Unscrambler applications.
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Stage of Project | The Unscrambler® Family Application | Tools and Expected Outcome | |
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Initial clinical trial on the newly developed API |
Assess if there are special groupings, increased responses to the new drug in various demographics using Principal Component Analysis (PCA) or Cluster Analysis and Univariate Statistical Tests. |
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Prepare pre-formulations to assess the stability of the new API with various excipients and assess stability under pilot scale manufacturing conditions |
Use Mixture-Process designs to optimize the Critical Quality Attributes (CQA’s) of the new formulation and identify the Critical Process Parameters (CPP’s). |
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Optimize the formulation to match the process and define the Design Space. |
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Scale the process up to full production and isolate critical process points for real time monitoring. |
Use Experimental Design to identify key process stages that need attention during scale up. |
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Develop processes using Quality by Design (QbD) and the principles of ICH Q8. |
Validate the process using the minimum number of trials. Isolate control points and use rapid sensors to monitor these processes in real time using the principles of Process Analytical Technology (PAT) and Multivariate Analysis (MVA). |
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Develop process models for monitoring the progress of a bio-reactor, or the drying cycle of a product. |
Develop process trend models using Principal Component Analysis and Multiblock/Batch Modelling. |
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Utilize these models in real time quality control and process investigation applications. |
Develop predictive models of drug potency / moisture content using Partial Least Squares (PLS) Regression. |
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Utilize the models in 3 rd Party Quality Management Systems (QMS) with The Unscrambler Online Predictor/Classifier. |
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Achieve the Pharmaceutical Quality Management System (PQS) described in ICH Q10. |
Use the knowledge gained from the QMS for Continuous Improvement (CI) and improved maintenance strategies. |
From the development of newer, more efficient fuel products to the development of novel materials for wind generators, The Unscrambler® family of products can assist in the development and monitoring of products and applications for the Energy Sector. Some applications and the corresponding Unscrambler tools are described below.
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Process/Development Application | The Unscrambler® Family Application | Tools and Expected Outcome | |
Gasoline blending operations. |
Employ Near Infrared Spectroscopy and Partial Least Squares (PLS) models to determine the optimal blending conditions. |
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Use Linear Discriminant Analysis (LDA), or Support Vector Machines(SVM) to classify fuel and feedstock types. |
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Develop lightweight materials able to withstand rugged environmental conditions. |
Use Mixture-Process designs to optimize components in novel materials. |
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Simultaneously achieve all desired properties using Numerical Optimization. |
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Determine the best location for establishing wind generator farms. |
Using Principal Component Analysis (PCA) or Regression Modelling, to investigate climatic conditions of various potential locations. |
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Locate the next biggest oil deposit. |
Using Principal Component Analysis (PCA), Regression Modelling or Cluster Analysis with geochemical data to isolate potential new oil sources. |
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Assess the overall operational efficiency of power stations and hydroelectrical facilities. |
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Simultaneously monitor all parts of a facility using multiple inputs and measure the efficiency of a plant using MVA models and The Unscrambler Online. |
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Classify agricultural products based on their potential yields or monitor bioreactors for biofuel applications. |
Combine MVA and Near Infrared Spectroscopy to classify the quality of grains or waste oil deliveries to get the best possible feedstocks and monitor the progression of bio-fermenters in real time for ethanol production. |
Designing new and improved products, such as household cleaning products that are environmentally friendly, or producing new fertilizers that don’t leave nasty residues are some of the challenges of product development in the chemical sector. The ability to manufacture effective products from “Greener” materials is set to dictate the direction of manufacturing in this sector over the coming years. Use The Unscrambler® family of products in the following stages of new product development.
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Stage of Project | The Unscrambler® Family Application | Tools and Expected Outcome | |
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Make test formulations based on new materials for cleaning products, adhesives, paint and coating materials. |
Develop new formulations in a systematic way using Mixture Designs and optimize the product attributes. |
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Look for desired conditions to achieve simultaneous properties in a product. For example, minimize organic solvent, improve drying time, reduce catalyst usage and attain environmentally friendly paint products. |
Using the individual optimization models developed in The Unscrambler®, determine if there is a formulation that simultaneously meets all of your desired criteria using Numerical Optimization. |
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Design and improve the way the products are manufactured. |
Using Principal Component Analysis (PCA) or Regression Modelling, determine which process steps / parameters influence the quality of the product. |
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Monitor the quality of the manufacturing process used to produce the new product. |
Use predictive models to ensure real time quality as the product is being made. |
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Assess the impact and success of the newly developed product on the market, or assess whether the smell characteristics, for instance of some products can be improved. |
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Develop Preference Maps on new products in regions.
Employ trained sensory panels to improve sensory attributes of products, including smell, appearance and texture |
Designing new products to meet consumer segment needs, or improving existing products is a major economic driver for most food and beverage companies. A multivariate approach to such problems, using The Unscrambler family of products is the best development strategy for combining consumer, sensory and process data, i.e. define the market you want to target and use designed experiments to achieve desired products. The typical steps involved in the development of a new snack food product and the corresponding CAMO product may include
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Stage of Project | The Unscrambler® Family Application |
Tools and Expected Outcome | |
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Market segmentation based on product preferences, i.e. the choice of potato type for a particular region. |
Using Cluster Analysis, Principal Component Analysis (PCA) or the new L-PLS method for finding similar consumer groups. |
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The training and assessment of sensory panellists so that the correct judgements are made on new and existing products. |
For assessing the quality of agreement between panellists in the selected group. |
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Designing “prototypes” of a new product for sensory panel evaluation. |
Using the Xperiment design module, develop designed formulations that best cover the expected variations in the new product. |
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Trialling the prototype products with a trained sensory panel and a selected consumer segment. |
Using Preference Mapping (PCR/PLS) to isolate a prototype formulation that best suits a consumer segment and provides new insights into the product. |
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Formulation optimization to make the product acceptable to the widest possible consumer segment. |
Using specific preference criteria develop a formulation, based on the prototypes, that best meets the widest possible consumer segment. |
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Develop the new product and assess its acceptance into the market. |
Use L-PLS to provide an overall acceptance map of the new product and gauge its success. |
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Monitor the quality of the manufacturing process used to produce the new product. |
Use predictive and classification models to ensure real time quality as the product is being manufactured. |
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