A long-standing ACD customer developed a new food grade product in 2012 and scaled up to commercial production in 2013. The product applications were very sensitive to the presence of any darker particles in the final powder so the use of fine mesh sifting screens was required to meet the customer’s specifications. This sifting generated a substantial amount of powder that contained an excess of dark particles and could not be used by ACD’s customer. As a result, the material containing dark particles had to be discarded as waste and the early yields for the product were between 75-85%.
Both ACD and the customer were very interested in increasing the product yield to above 90% by either reducing the amount of material containing excessive dark particles or by developing a procedure to remove the dark particles and recover the waste material.