Extending UK manufacturing capacity through the introduction of continuous processing unit operations

Lead Research Organisation: University of Cambridge
Department Name: Engineering

Abstract

A collaborative R&D project to design, build and trial a modular unit for the continuous production of a range of market
leading anionic surfactants, currently manufactured in the UK by Croda Europe Ltd. Based on patented Continuous
Oscillating Baffle Reactor (COBR) technology, the project will deliver a new process for the manufacture of existing
products, with significant improvements in operational and capital costs and process sustainability without impacting
product quality. Processes are specifically designed for integration with existing batch manufacturing assets to provide
increased capacity without the need for new supporting infrastructure and extended footprint.
The consortium believes that the 30% targeted reduction in operational costs, combined with reduced capital requirements
will make investment in UK manufacturing a competitive option in a global market. This industry led, four partner
consortium (Croda, CPI, University of Cambridge, Institute for Manufacturing and NiTech) will establish technical and
commercial viability of the concept; de-risking Croda future commercial investment in the proposed technology. The
impact of this strategy to create flexible manufacturing capacity on existing business models will be explored.

Planned Impact

PROJECT PARTNERS - Deep engagement with the research outputs will be achieved first and foremost with the project
partners - Croda Europe Ltd, CPI, NiTech and University of Cambridge - through the development of the underpinning
knowledge ideas and innovation, and through the subsequent use and application of new ideas and tools arising from the
project. The project aims to apply a novel technology (COBR) developed by NiTech and commercialise in the chemical
manufacturing sector, and develop an appropriate business model for its market adoption.
INDUSTRY - The University of Cambridge regularly presents in open forums across industry and also runs workshops to
showcase tools for these audiences, ensuring a wide awareness and opportunities to engage with the project insights and
outputs. University of Cambridge has also partnered with non-industry specific forums such as IEMA, KTNs, and the
2Degrees network who have a large and diverse membership and provide an excellent route to broad multi-sector
dissemination. The University of Cambridge also has developed effective methods for dissemination of project outputs,
including through executive education, in-companies training, consultancy licensing as well as the more traditional
academic approaches.

ACADEMIC COMMUNITY - The EPSRC Centre for Industrial sustainability represented in this project by the Institute for
Manufacturing at the University of Cambridge affords a number of pathways to impact. The University of Cambridge (UoC)
will disseminate the research results and knowledge developed in this project to its academic community in the form of
papers, conference presentations, workshops and teaching, whilst sharing the tools and insights with its extensive
industrial network.

UK ECONOMY - This project seeks to defend and grow UK chemical manufacturing through (i) development of new
efficient processes with a lower operating cost base (30% reduction targeted), (ii) ability to compete on price with Chinese
producers (iii) improved product environmental credentials- added value and (iv) ability to bring products to market faster
and develop new future markets. The project will enable industrial demonstration of a novel COBR technology followed by
increased licensing opportunities. The project will de-risk and increase the potential for UK investment- positively
benefiting the local area through the retention of existing job and increasing future employment and local skills
development opportunities. Environmental benefits include lower energy processing, less use of water, removal of process
solvents and hence lower VOC emissions, reduced waste through better process control and reduced equipment cleandown
volumes. Outside of the consortium, the UK benefits from improve environmental emissions.

Publications

10 25 50
 
Title Woodpeckers, After All 
Description Dr Curie Park published an essay book 'Woodpeckers, after all' for Korean readers on 1st Aug. Having been inspired by woodpecker spotting in the last three places she called home i.e. Gangneung, her first marital home; Cambridge, her current UK home; and Seoul, her latest marital home in Korea, the woodpecker symbolises a thriving lifestyle that benefits neighbours with wit and style. In this tiny book she introduces her daily stride towards sustainable life beyond her bread and butter, sustainability research. The 24 hilarious, touching or outrageous stories include; refusing single-use plastics, going flexiterian, planting a tree at a secret location near IfM, second-hand clothes hunting and having a child in the 21st Century and beyond. Although the Korean text would be inexplicable for most of the IfMers, it didn't stop many of them appearing in the book. The dark night quest for hedgehogs to Steve's garden with Steve and Ian, the lunchtime hyenas after the leftover sandwiches in the common room, the communal recycling shelf at Martin and Paulo's rented house, the teatime birding club with Aloisius, to Florian's secondhand sewing machine and the Kimchi making session with Paulo and Kirsten are only to name a few! Fingers crossed the English version may one day see the light of day. 
Type Of Art Creative Writing 
Year Produced 2018 
Impact Dr Park hopes this book would approach the Korean readers in a friendly manner, and encourage them to engage with easy and enjoyable sustainable actions in their everyday life. 
 
Description By delivering a new manufacturing process specifically designed for integration with existing batch manufacturing assets, the project permitted increased capacity without the need for new supporting infrastructure and extended footprint. The 30% targeted reduction in operational costs, combined with reduced capital requirements, made the case for investing in UK manufacturing as a competitive option in a global market.
Exploitation Route The project provided evidence about ways to achieve manufacturing flexibility through easily variable production volumes to match demand, along with rapid product changeover and customisation with minimal waste. It is therefore expected to position the UK as a leader in next generation processes and business model innovations.
Sectors Chemicals

 
Description The project has informed the design of an evaluation framework for business model transformation. Meant to prompt strategic decision making, the framework identifies a number of key internal factors (including strategic fit, costs, existing capital investment, value, volume) and external factors (including regulation, supply chain management, customers' demand for value, quality and delivery, technology readiness for implementation, and sustainability impact of long-term industry trends). It influences 4 possible dimensions when considering manufacturing processes for chemical products: suitability for batch, continuous, a combination of batch and continuous, and fully continuous. The tool further enabled an evaluation of the key challenges to overcome for implementation by supporting a structured review of technology bias, technological limitations, culture inertia, ability to change mindsets, IP, impact, skills and capabilities. As a result, Croda has started implementing the new technology and identified from the assistance provided by CIS not only a solution to improve the rate of deployment by a factor of 3 but also a new business model protective of their know-how and IP while allowing for distributed manufacturing at a reduced environmental, economic and social cost. Since 2020 we have been using these outputs across the Singapore chemical industry as part of future roadmapping within the Singapore CREATE framework.
First Year Of Impact 2017
Sector Chemicals
Impact Types Societal,Economic,Policy & public services

 
Description Member of Academic Expert Group for the BEIS Industrial De-carbonisation Strategy
Geographic Reach National 
Policy Influence Type Participation in a guidance/advisory committee
Impact Adding knowledge of what works and what does not work in the practice of industrial de-carbonisation into BEIS policy on de-carbonisation
 
Description Member of BEIS Supply Chain External Expert group
Geographic Reach National 
Policy Influence Type Participation in a guidance/advisory committee
Impact Adding Net Zero knowledge into BEIS policy making for Supply Chain improvement
 
Description Member of UKRI Manufacturing Made Smarter Advisory Group
Geographic Reach National 
Policy Influence Type Participation in a guidance/advisory committee
Impact Revised the strategy for Manufacturing Made Smarter to include environmental goals for the first time.
 
Description Training scheme for the UK Department for Transport
Geographic Reach National 
Policy Influence Type Influenced training of practitioners or researchers
 
Description Arts & Humanities Research Council
Amount £5,450,510 (GBP)
Funding ID AH/S002804/1 
Organisation Arts & Humanities Research Council (AHRC) 
Sector Public
Country United Kingdom
Start 10/2018 
End 03/2023
 
Description EPSRC Cranfield Digital Re-distributed Manufacturing Studio
Amount £24,928 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 05/2016 
End 02/2017
 
Description EPSRC IAA KTF
Amount £47,018 (GBP)
Organisation University of Cambridge 
Sector Academic/University
Country United Kingdom
Start 04/2019 
End 03/2020
 
Description EPSRC IAA Post Doc Placement
Amount £9,914 (GBP)
Organisation University of Cambridge 
Sector Academic/University
Country United Kingdom
Start 12/2018 
End 03/2019
 
Description H2020-IND-CE-2016-17/H2020-SPIRE-2017
Amount € 1,049,481 (EUR)
Funding ID 768748 
Organisation European Commission 
Sector Public
Country European Union (EU)
Start 11/2017 
End 04/2020
 
Description H2020-WIDESPREAD-2016-2017/H2020-WIDESPREAD-05-2017- Twinning
Amount € 996,390 (EUR)
Funding ID 810764 
Organisation European Commission H2020 
Sector Public
Country Belgium
Start 10/2018 
End 09/2021
 
Description IUK December sector competition: Open
Amount £572,566 (GBP)
Funding ID 104387 
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 11/2018 
End 09/2020
 
Description TransTextile. Developing High Value Products from Industrial Waste in Sri Lanka
Amount £36,614 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 08/2016 
End 03/2017
 
Description University of Cambridge Impact Acceleration Account - Cambridge Method for Value Generation Tools Website
Amount £6,996 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 11/2016 
End 03/2017
 
Title Business model innovation in the chemical industry 
Description Project concerned with exploring the implications of adopting continuous manufacturing techniques on the value propositions and business models of commercial partners, including the supplier and user companies. 
Type Of Material Improvements to research infrastructure 
Provided To Others? No  
Impact Extension of the use of the business model tools in a context with companies having a commercial relationship. 
 
Title Sustainable Business Models for process industry 
Description This research is studying Sustainable Business Models for the process industry. Flexible manufacturing is being introduced to replace continuous manufacturing, which is the standard in process industry. Flexible manufacturing has sustainability benefits but there are very few studies on the business models for flexible manufacturing in the process industry. 
Type Of Material Improvements to research infrastructure 
Provided To Others? No  
Impact Impacts are expected to be on Sustainable Business Models for the process industry. There are very limited studies in this area. 
 
Title TCM Model 
Description Transformation towards continuous manufacturing model 
Type Of Material Data analysis technique 
Provided To Others? No  
Impact Increase understanding of the challenges in the transformation from batch to continuous manufacturing in the chemical industry 
 
Description Building Future Leaders - CIS Annual Cohort Retreat January 2017 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Postgraduate students
Results and Impact Through the Cohort Development Programme the Centre is meeting its goal to increase the capacity for change, by developing researchers who not only have deep technical skills derived from their research, but a broader understanding of business and sustainability. This understanding cannot be built solely from textbooks, papers and laboratories, but is strengthened and deepened by engaging with practice, exchanging with peers and broadening horizons of experience.
In order to support these needs the Centre developed the cohort programme, bringing together students of manufacturing, design and industry with a common interest in sustainability. The cohort development programme is there to support research students from across Centre institutions and from the EPSRC Centre for Doctoral Training (DTC) in Sustainable Materials and Manufacturing, but we have welcomed members from across the UK and the international research community.
Over the last 5 years, the programme has provided a range of opportunities for researchers to gather and engage in activities to improve their research practice, build networks and expand personal horizons. Events have ranged from research practice - helping understand the tool building process - to communication skills, practicing how to communicate research ideas succinctly to industry. The community has also exploited social media such as Facebook to maintain contact between events and share the latest news and conferences. The cornerstone of the programme is an annual retreat which brings students, researchers, senior academics together to develop shared understanding, and personal vision for their role in the future of manufacturing. In 2016 62 attendees were drawn from 11 UK institutions
Year(s) Of Engagement Activity 2016
 
Description Business Modelling Workshop for FlexMan 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Business Modelling Workshop was conducted at CPI, Sedgefield. The Centre's Value Mapping tool for Business Modelling was used in a workshop with CPI and NiTech. This helped identify the value opportunities for those participants in the larger project.
Year(s) Of Engagement Activity 2016
 
Description C Park: Member of the Green Impact Team, IfM, University of Cambridge 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Postgraduate students
Results and Impact We have now established a Green Impact team here at the IFM. Green Impact supports and encourages departments and colleges across the University in reducing their
environmental impacts. The first meeting was held on 19 November which was attended by Peter Lumb from the Environment and Energy team, who briefed us on the Universities accreditation scheme. The IfM Team is a mixture of staff and students willing to take on the challenge of making a difference. With the guidance of a workbook we will be working towards the Bronze award for the building. Please look out for posters and notices around the building explaining what we are hoping to achieve and contact any of the Team for help or to bring ideas forward. Plus look out for the Green Impact buns talk early in the New Year. The team is Becca Clarke, Anna Quincey, James Wood, Rebecca Fowler (DIAL),
Shane Strawson (Teaching office), Andy Nightingale(Facilities manager) and Curie Park (Sustainability).
Year(s) Of Engagement Activity 2018
 
Description CIS Annual Conference presentation by K Zhang 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation of the results from Engineering Dept MET long project on the transformation towards continuous manufacturing
Year(s) Of Engagement Activity 2016
 
Description FlexMan Press Release by NiTech 
Form Of Engagement Activity A press release, press conference or response to a media enquiry/interview
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact NiTech Press Release Titled: NITECH WINS MAJOR >£1m INDUSTRY-LED PROJECT
Press Release dated: Feb 2016
Year(s) Of Engagement Activity 2016
URL http://www.nitechsolutions.co.uk/nitech-wins-major-1m-industry-led-project/
 
Description FlexMan Press Release from CPI 
Form Of Engagement Activity A press release, press conference or response to a media enquiry/interview
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact Press release Titled: CPI in UK collaboration to develop world class surfactant manufacturing techniques
Dated: 16 Dec 2015
Year(s) Of Engagement Activity 2015
URL http://www.uk-cpi.com/news/collaboration-to-develop-new-surfactant-manufacturing-techniques/
 
Description Flexman launch in IfM Newsletter 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Doroteya Vladimirova and Sudhir Rama Murthy launched a new two-year project for CIS, in collaboration with Croda, the Centre for Process Innovation (CPI) and NiTech Solutions. The CIS team will investigate new business models for the adoption of NiTech's continuous oscillating baffle reactor (COBR) technology, and the shift from batch to continuous manufacturing in the process industry. The project is part-funded by Innovate UK and EPSRC in the 'Flexible Manufacturing' competition.
Year(s) Of Engagement Activity 2016
 
Description Industry visit to CPI, Sedgefield 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Industry/Business
Results and Impact Researcher visited CPI, Sedgefield, to understand the technology at the centre of this project. The sharing of ideas enabled developing the collaboration for the workshop.
Year(s) Of Engagement Activity 2016
 
Description Pilot policy workshop in France 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Policymakers/politicians
Results and Impact As part of CIS engagement and outreach activities, a workshop was organised to explore how the value exchange approach developed by CIS researchers to innovate business models in a sustainable way could be applied in a policy context. Taking place in France, in a small town in Normandy (Dozulé, 2000 inhabitants), the Value Explorer tool from the Cambridge Method for Value Generation was used to assist the mayor with members and staff of the town council in discovering new opportunities for a local policy issue. The workshop led to interesting considerations about the use of the Value Explorer as a way to inform and de-risk policy design and development, and to better frame policy challenges.
Year(s) Of Engagement Activity 2017
 
Description Professor Steve Evans contributes to Future of Engineering report 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Policymakers/politicians
Results and Impact 2018 is the UK's Year of Engineering, the government campaign to promote and celebrate one of the country's most dynamic industries. As the year comes to an end, what are the concerns occupying the sector's leaders? The Future of Engineering special report, published in The Times, covers how a lack of sufficient funding for research and development is holding innovation back, and addresses what can be done to encourage more women to join the industry. It explores the new importance of so-called soft skills in engineering graduates and the need for an overhaul of the patents system. Also featured is comment on how engineering can spearhead the fight against climate change and an infographic on the work to be done to counter the sector-wide talent shortage.

The report features an opinion column by the IfM's Professor Steve Evans who discusses the ongoing challenge faced by sustainability engineers.
Year(s) Of Engagement Activity 2018
URL https://www.raconteur.net/business-innovation/engineering-climate-change
 
Description Re-Distributed Manufacturing EPSRC Sandpit 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Other audiences
Results and Impact Discussed novel approaches to re-distributed manufacturing, and the relevance of flexible manufacturing to sustainability.
Year(s) Of Engagement Activity 2016
URL http://www.recode-network.com/
 
Description S Evans: Change Fashion Challenge Forum and Workshop, The New York Academy of Sciences, USA 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact The Change Fashion Challenge (CFC) focuses on creating innovation to pioneer the future of fashion and create a new sustainable ecosystem in the fashion industry. This means innovation throughout the entire product lifecycle, toward a circular and regenerative model -- changing the way garments are designed and produced, shipped, bought, used and recycled by introducing disruptive science and technology and new business models.

The Change Fashion Forum and Workshop was an invitation-only event bringing together leaders from the fashion industry, academia, and non-profit organizations to begin the development of a prioritized sustainable fashion research agenda and roadmaps for the priority areas identified in the agenda.
Year(s) Of Engagement Activity 2018
URL https://www.nyas.org/events/2018/change-fashion-challenge-workshop/
 
Description S Evans: Falling Walls Conference 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact On 9 November, Prof Steve Evans was a speaker at the Falling Walls Conference in Berlin. Falling Walls is the International Conference on Future Breakthroughs in Science and Society, an annual global gathering of forward thinking individuals from 80 countries organised by the Falling Walls Foundation. Each year on 9 November - the anniversary of the fall of the Berlin Wall - 20 of the world's leading scientists are invited to Berlin to present their current breakthrough research. The aim of the conference is to:
• identify trends, opportunities and solutions for global challenges and discover international breakthrough research.
• connect outstanding researchers from different disciplines and support the interdisciplinary exchange of ideas internationally.
• build bridges between business, politics, academia and the arts.
• promote the latest scientific findings among a broader audience.
• inspire people to break down walls in science and society.
Steve Evan's talk looked at understanding how industry can bring environmental and social sustainability concerns into its design and manufacturing practices. In his advisory and policy roles, he put emphasis on urgent & practical change now and system level change that others hope for a sustainable future.
Year(s) Of Engagement Activity 2018
URL https://www.falling-walls.com/about
 
Description S Evans: Leaders on Purpose meeting 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact The Leaders on Purpose CEO Summit brings together some of the world's top visionaries and leaders to accelerate a new kind of leadership at the forefront of a new business logic
- one that, at its core, integrates purpose and profit. Why? Because solving humanity's most pressing challenges is both the right thing to do and an unprecedented business opportunity.
The Summit, hosted by LEADERS ON PURPOSE in collaboration with partners from PROJECT X highlights critical lessons learned from the comprehensive Leadership for the 21st Century & Beyond study. Interactive sessions dive into insights on leadership strategies, attitudes and opinions of the world's top CEOs and uncover how progressive CEOs leverage purpose in shaping a new business logic and cross-sectoral partnerships. The eventl shares powerful new organizational models and strategies that have allowed the world's top leaders to thrive on the cutting edge of their markets and industries.
Year(s) Of Engagement Activity 2018
URL https://www.leadersonpurpose.com/
 
Description S Evans: Met with ten CSaP Policy Fellows 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Professional Practitioners
Results and Impact Since 2009, CSaP have pioneered new ways of bringing together public policy professionals and academics to learn from each other, building relationships based on mutual understanding, respect and trust. The experience and diversity of this unique network provides fresh perspectives and critical challenges to conventional thinking, and helps research from all disciplines contribute more effectively to society.
Year(s) Of Engagement Activity 2018
URL http://www.csap.cam.ac.uk
 
Description S Evans: Presented the Future Cities Design to the Mayor's office in the Sino-Singapore Tianjin Eco-City, near Beijing, China 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Policymakers/politicians
Results and Impact Prof Steve Evans presented the Future Cities Design to the Mayor's office in the Sino-Singapore Tianjin Eco-City, near Beijing, China. "The city of the past is likely not the city of the future-climate change is bringing an end to the traditional model. Harvard Business School faculty are thinking along with government leaders and business practitioners about how to create sustainable places to live and work. In addition to innovative approaches to upgrading urban slums, brand-new, environmentally sound cities will emerge "from scratch" in sparsely populated areas of China, India, and elsewhere. These instant cities-by some estimates $500 billion will be invested in them in the next decade alone-will be designed, located, and built to be more livable and more competitive. That means densely populated, vertical, highly energy-efficient urban centers, featuring excellent intra- and intercity mass transportation. Macomber estimates that China may build possibly dozens of such cities, each housing 10 million people, by 2050."
Year(s) Of Engagement Activity 2018
URL https://hbswk.hbs.edu/item/designing-cities-for-a-sustainable-future
 
Description Sustainability Leadership Labs: Business model innovation for the circular economy 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact University of Cambridge Institute for Sustainability Leadership (CISL) Labs bring together professionals to test and challenge cutting-edge responses to global problems. Open to all our alumni and senior industry practitioners, these two-day sustainability workshops held four times per year in Cambridge, are an opportunity for professional development, co-creation and networking - all with real application to your company or organisational situation. Use cutting-edge business model innovation tools designed by the University of Cambridge to discover how to transform your business to deliver uncaptured and sustainable value throughout the lifecycle, and design value propositions for the stakeholders in your business networks.

Is your business getting the full benefit of the value you are creating for customers and other stakeholders?

Could your current business model be actively destroying value and ultimately affecting the organisation's ability to capture value in the long run?

How do you identify resource synergies that will enable circular business models?

Answers to these questions will be explored during the two-day short course, through the business model innovation tools, industry case studies and insights from leading research on the circular economy.
Year(s) Of Engagement Activity 2019
URL https://www.cisl.cam.ac.uk/graduate-study/sustainability-leadership-labs