Benefits of a Testing-Backed Tolling Facility

This article was authored by:

Carrie Carlson
Technical Writer

Tolling, or toll processing, is becoming an increasingly common approach to meeting new or expanding production requirements. Further, the role of the tolling facility is evolving and expanding beyond simple production runs. 

Whether producers are looking to develop a new product, expedite the commercialization process, or simply outsource excess capacity, toll processors backed by in-house testing provide producers with more comprehensive support, offering significant value to the tolling process.

When looking for a toll processing facility that fits their unique production needs, producers should opt for a facility with in-house testing capabilities.

Benefits of In-House Testing

While the needs of producers vary considerably, there are many potential benefits to working with a tolling facility that offers integrated testing options: 

Assistance in Process & Product Development

Testing-backed tolling facilities help to de-risk the commercialization and scale-up process by adding another layer of support and expertise during critical process and product development stages. This often includes:

  • Assessing process feasibility
  • Evaluating process variations
  • Producing samples for market testing
  • Aiding in formulation development
  • Recommending best available technologies
  • Addressing quality control concerns
  • Improving process efficiency
  • Streamlining the scale-up process

Continuity

Similarly, when producers are working through the many process development stages, continuity is crucial to advancing the project successfully and in a timely manner.  

Producers utilizing separate testing and tolling companies for process or product development are often faced with the challenges that come along with siloed information; lack of information sharing, miscommunication, unclear division of roles, and more. This can slow down progress substantially and create many frustrations along the way. 

By selecting a toller with internal testing capabilities, the gaps between batch testing and tolling are bridged, avoiding the pitfalls of employing multiple facilities and providing a streamlined experience. 

Small-Scale Troubleshooting

Where a producer may be tasked with going back to the drawing board when troubles arise, toll processors offering test facilities have the capability and the resources to troubleshoot and work through unexpected process issues, which often means the difference between the process going forward or hitting a wall. 

This benefit is particularly evident in the FEECO Tolling Center, where those who assist in tolling also work in the FEECO Innovation Center. This background in small-scale testing provides valuable expertise in working through process issues that may arise during the tolling process.

Process Improvements

When a tolling facility is more than just outsourced production, producers often see benefits from an extra set of eyes, particularly when those eyes have a process development background. 

Experienced tollers with the support of a testing facility are able to recognize process inefficiencies that may not be known by the producer. In addition to identifying a potential issue, toll processors can then test their theories for validation prior to implementing changes on a larger scale when on-site testing is at their disposal. 

Process inefficiencies that often go unnoticed include:

  • Flow problems
  • Energy use
  • Small changes in product quality
  • Low on-size product rate
  • Inconsistent feeds

Faster Time to Production 

Utilizing a tolling facility with in-house testing capabilities streamlines the time to production when developing a new process or product. Tollers are able to work through problems and minimize wasted time and resources. When initial commercial production is handled through the toller, producers have the added benefit of seeing their new process operating successfully at scale.

When Testing is Critical

While testing can offer many benefits to the tolling process, it is not always necessary, or may be required in varying amounts depending on the project at hand. 

The benefits listed here are particularly advantageous when working with complex agglomeration, granulation, or coating processes, such as those carried out in the FEECO Tolling Center. In processes such as these, where nuances in material behavior can threaten the success of a project, expertise and the ability to work through issues is essential. 

Conclusion

Choosing a tolling facility supported by in-house testing capabilities provides many benefits, including assistance in process and product development, troubleshooting, and streamlining the road to commercial-scale production. 

The FEECO Tolling Center is a cutting-edge facility backed by our in-house batch and pilot testing facility, The Innovation Center. Producers looking for more than a toller will find the comprehensive support they need at FEECO. For more information on the FEECO Tolling Center, contact us today!

About the Author . . .


Carrie Carlson is a technical writer and visual designer.

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