Smart Continuous Nanoparticle Manufacturing.

Aims:
The project is envisioned to enable smart continuous nanoparticles manufacturing by developing a modular platform technology for nanoparticle production. Development of methods for real time characterisation of particle size, composition and morphology coupled with computerised reactor control the project will contribute towards algorithmic driven self-optimisation of nanoparticle formation and production. Key technology output includes real-time particle analysis methods, a robust nanoparticle process and control environment and an enabling technology for intensified data driven development.

Methodology:
The initial focus of the work will be identification of polymeric nanoparticles and compatible encapsulant targets relevant to biopharmaceutical industries by literature searching and collaboration with the industrial partners.

The project will exploit the Cognitive Chemical Manufacturing EPSRC project control platform and further develop an automated control system integrating mixing and synthesis, separation and purification of nanoparticles equipped with online analytics for monitoring of particle characteristics.

The platform's performance to deliver targeted nanoparticles and develop fundamental understanding of various nanoparticle types.

Potential Impact of Project:
This project aims to deliver an autonomous and rapid method for rapidly generating targeted nanoparticles. These materials have significant societal and economic impact (for example in the development of vaccines and targeted release medicines). Accelerated development of such materials will enable a faster route to patients and may therefore save lives whilst also providing economic returns. More generally the integration of machine learning within an industrial workflow provides experience to the whole project team (both industrial and academic) which may result in wider impact at AstraZeneca and the University of Leeds as Industry 4.0 practices are incorporated within normal working.

Expected Deliverables:
Month 4 - Literature review of polymeric nanoparticle generation routes
Month 9 - Online measurements with SAXS, DLS, UV-Vis of chosen nanoparticle System
Month 18 - Established platform integrating control, online analysis and feedback optimisation
Month 30 - 2 Case study optimisations of polymeric nanoparticles using machine learning methods
Month 36 - Benchmarking of autonomous method vs manual optimisation

The CDT in Molecules to Product has the potential to make a real impact as a consequence of the transformative nature of the underpinning 'design and supply' paradigm. Through the exploitation of the generated scientific knowledge, a new approach to the product development lifecycle will be developed. This know-how will impact significantly on productivity, consistency and performance within the speciality chemicals, home and personal care (HPC), fast moving consumer goods (FMCG), food and beverage, and pharma/biopharma sectors.
UK manufacturing is facing a major challenge from competitor countries such as China that are not constrained by fixed manufacturing assets, consequently they can make products more efficiently and at significantly lower operational costs. For example, the biggest competition for some well recognised 'high-end' brands is from 'own-brand' products (simple formulations that are significantly cheaper). For UK companies to compete in the global market, there is a real need to differentiate themselves from the low-cost competition, hence the need for uncopiable or IP protected, enhanced product performance, higher productivity and greater consistency. The CDT is well placed to contribute to addressing this shift in focus though its research activities, with the PGR students serving as ambassadors for this change. The CDT will thus contribute to the sustainability of UK manufacturing and economic prosperity.
The route to ensuring industry will benefit from the 'paradigm' is through the PGR students who will be highly employable as a result of their unique skills-set. This is a result of the CDT research and training programme addressing a major gap identified by industry during the co-creation of the CDT. Resulting absorptive capacity is thus significant. In addition to their core skills, the PGR students will learn new ones enabling them to work across disciplinary boundaries with a detailed understanding of the chemicals-continuum. Importantly, they will also be trained in innovation and enterprise enabling them to challenge the current status quo of 'development and manufacture' and become future leaders.
The outputs of the research projects will be collated into a structured database. This will significantly increase the impact and reach of the research, as well as ensuring the CDT outputs have a long-term transformative effect. Through this route, the industrial partners will benefit from the knowledge generated from across the totality of the product development lifecycle. The database will additionally provide the foundations from which 'benchmark processes' are tackled demonstrating the benefits of the new approach to transitioning from molecules to product.
The impact of the CDT training will be significantly wider than the CDT itself. By offering modules as Continuing Professional Development courses to industry, current employees in chemical-related sectors will have the opportunity to up-skill in new and emerging areas. The modules will also be made available to other CDTs, will serve as part of company graduate programmes and contribute to further learning opportunities for those seeking professional accreditation as Chartered Chemical Engineers.
The CDT, through public engagement activities, will serve as a platform to raise awareness of the scientific and technical challenges that underpin many of the items they rely on in daily life. For example, fast moving consumer goods including laundry products, toiletries, greener herbicides, over-the-counter drugs and processed foods. Activities will include public debates and local and national STEM events. All events will have two-way engagement to encourage the general public to think what the research could mean for them. Additionally these activities will provide the opportunity to dispel the myths around STEM in terms of career opportunities and to promote it as an activity to be embraced by all thereby contributing to the ED&I agenda.