Process Development and Optimization

Process Engineering

From Molecules to Manufacturing — Proven Results

At Eustone, we combine advanced materials expertise, process optimization, and scale-up capabilities to transform complex challenges into reliable, industrial-scale solutions. Our approach bridges the gap between lab-scale innovation and full-scale manufacturing — ensuring precision, efficiency, and quality at every stage.

Equipment & Material Engineering

Custom design, simulation, and lab setup for pharmaceutical and chemical processes.

Development & Process Optimization

Flow & batch technology, synthesis improvements, and performance tuning.

Formulation & Material Design

API & formulation engineering, stability testing, and custom material solutions.

Pharma Lifecycle Support

GMP troubleshooting, quality control, and compliance strategies.

our approach

Our Process Engineering Approach

We support clients from the earliest stages of development through to industrial implementation:

Challenge

A client’s crystallization process was underperforming — with only 70% yield and particle size distribution (PSD) outside specification. This affected both efficiency and final product quality.

Our Approach

Identified root causes using process analysis.
Applied DOE (Design of Experiments) to fine-tune solvent ratio, nucleation temperature, seeding, ageing, and cooling rates.
Used CFD simulations and AI-assisted tools to design a robust process.
Validated improvements at lab scale (5–500 mL) and scaled up to kilolab (3–20 L).
Prepared for industrial-scale implementation.

Results

Yield increased to 95%
PSD fully within target range on lab and kilolab scale
Stable, repeatable process ready for industrial production

work with us

Why It Matters

This project demonstrates how our integrated approach — from design to scale-up — delivers measurable improvements in yield, quality, and process stability. For industries where precision is critical, these gains translate into significant cost savings, faster time-to-market, and more reliable supply.  

Have a process challenge? Contact us bellow.