We understand that all labs are different, so while we’ve designed our products to be as flexible as possible, sometimes you’ll need something unique to your laboratory or application.
The Syrris R&D Team regularly work with chemists and chemical engineers across a range of industries to design, prototype, test, and build custom parts for our batch, flow, and scale-up chemical reactor systems.
The Custom Parts Team, along with the Regional Sales Executive involved, keep in regular contact with the customer throughout the custom parts process to ensure the purpose of the custom part is fully realized.
What custom parts are available?
Over the years the Syrris R&D Team has developed a range of custom parts – from stirrers, vessels, condensers, and other glassware – through to entire custom systems. We manufacture our own glassware so have complete flexibility.
How it works: the custom parts process
Many custom parts are simple variations on our existing parts – a shorter stirrer shaft or extra ports on a lid, for example. Some customers, however, require far more complex custom parts for their jacketed reactors or flow chemistry systems, such as automated bottom outlet valves (BOVs) or completely redesigned stirrer designs.
For these more complex custom parts requirements, the Custom Parts Team at Syrris uses a 4-step process when working with customers to produce custom parts for our batch and flow chemistry systems.
Step 1: Feasibility study
After initial discussions with the customer about what they’re trying to achieve, the Custom Parts Team perform a feasibility study to determine if it’s possible, how the part would need to function to perform its role and generate CAD designs of the part.
Step 2: Prototyping
Following approval from the customer on the feasibility study, the Custom Parts Team manufacture a prototype part to test it. During this part of the process, the customer may visit the Syrris office to see the part in action, or we’ll send a video recording to the customer. Several prototypes may be created to determine the best design for the custom part.
Step 3: Final design
Feedback generated from the prototyping stage is used to determine the final CAD design of the custom part, which is then sent to the customer for approval.
Step 4: Production
Following final design approval by the customer, manufacturing drawings are completed, and then the custom parts are manufactured. The full system is the built including the custom part, and the system is fully tested before being shipped to the customer.
Instructions for use/assembly are generated if required and added as an addendum to the operating manual of the system.
Xeros Technology Group customer story: a custom stirrer and gearbox
Xeros Technology Group has a mission to improve the sustainability of industrial laundry washing by providing technologies that dramatically reduce water consumption. Xeros Technology Group achieves this through their novel XOrb™ beads; these spheroidal polymer balls can be added to a wash load to create a gentle mechanical action, helping to remove dirt and stains using less detergent and at lower temperatures, which saves water and reduces cost.
Xeros approached Syrris to design a stirrer system that would mix 50 kilograms of their polymer beads to aid in their research and development. The custom stirrer was to be used with an Orb Pilot scale-up chemical reactor system in a 50 L vessel.
The feasibility study
We designed a helix-style stirrer and sent a document to the customer for approval prior to fabrication. The prototype was designed in a way to enable multiple single, double, and half-height helix configurations to be trialed for mixing and optimizing torque to speed ratio. A gearbox system was also designed to convert the stirring speed from the motor at a ratio of 5:1.
Prototyping the custom stirrer and gearbox
Following sign off from the customer, we manufactured and tested a prototype of the custom stirrer. This included making a test rig including a gearbox and test lid. The prototype was built with multiple indexing holes along the stirrer shaft; this enabled the R&D Team to test the mixing performance of single, double, and half-height helix configurations at varying angles.
The final custom stirrer and gearbox design
Following completion of the feasibility study and identifying the best design for the custom stirrer based on the customers’ mixing requirements, the production custom lid, stirrer, and gearbox assemblies were designed and CAD images were sent to the customer for approval. A flexible joint in the stirrer shaft was added to the design to offer some tolerance in stirrer motor alignment with the gearbox.
Production of the custom stirrer and gearbox
Following sign off, manufacturing drawings were completed, the parts manufactured, and the system built and tested. Instructions were also provided as an addendum to the Orb Pilot manual to cover the use of the custom parts.
The final result
Following the final build and testing, the custom stirrer and gearbox were shipped with the Orb Pilot scale-up jacketed reactor to Xeros Technology Group’s lab where it is now in use aiding their research and development.