Batch reactor cycles took 48 hours, limiting throughput

Implemented continuous flow design reducing cycle time to 12 hours, quadrupling output

Energy consumption per ton of product was 150 kWh

Optimized heat integration saved 30 kWh/ton, cutting energy cost by 20%

Yield hovered at 78% due to sub‑optimal residence time

Adjusted reactor residence time and temperature, raising yield to 92%

Manual temperature control caused frequent deviations

Installed advanced PID controller, maintaining ±0.5 °C variance

Downtime from fouling was 15 days/year

Introduced anti‑fouling coating, reducing downtime to 3 days