Inside edition 3 of the Circular Factory Program: The art of process design 

During expert sessions, the group explored the complexities of process steps, technology choices and scaling challenges. They got into the nitty-gritty of balancing CapEx and OpEx, designing systems for future electrification and leveraging the mass and heat balance to maximize efficiency.

Key insights from the morning included:

• Aligning TRL/MRL: Aligning technical readiness (TRL) with manufacturing readiness (MRL) is crucial to avoid costly missteps when scaling.
• Scale-up / scale-down approach: Scaling isn’t just about size. Using scaled-down pilot tests can validate critical steps while keeping costs manageable.
• Co-manufacturing vs. In-house production: Weighing speed-to-market against IP control, Arjen guided startups through the trade-offs of outsourcing versus owning production.

In the afternoon, we took the morning’s insights to the production floor with a visit to Caffe Inc.’s pilot plant. We also celebrated their latest milestone in scaling operations: securing a major feedstock provider!

Key take away

Process design is more than just scaling equipment or managing feedstock—it’s about exploring all the layers that make a scalable circular process. This includes refining business models, optimizing your outsource/DIY strategies, and aligning readiness levels. As Bart van den Heuvel from Circular Factory explained, “This is why we changed the name of the pillar from ‘Plant Design’ to ‘Process Design & Technology development.’ Scaling doesn’t always mean building your own plant—it’s about optimizing your production process and considering options like co-manufacturing that can help startups grow.”

The next Deep dive day will focus on Finance. Stay tuned for another update. In the meantime, check out the profiles of the participants and learn more about their stories.

The third edition of the Circular Factory program is made possible thanks to our financial partners: Gemeente Rotterdam, Stichting Ondernemersbelangen Rotterdam, the Rabo Foundation and Invest-NL.