Case Study: Qenos achieves 6‑month faster HDPE product development and $135,000/year savings with Aspen Technology (Aspen Polymers™)

The Innovation Fast Track Saving Time and Money in New Product Development

Qenos, a Melbourne‑based HDPE manufacturer, needed to get custom‑tailored products to market faster while optimizing challenging batch processes and reducing side reactions that produced off‑spec material. With no dedicated pilot plant, Qenos worked with Aspen Technology using Aspen Polymers™ to model and understand dynamic reactor behavior and guide development without excessive production trials.

Aspen Technology built a data‑driven batch model using plant historian data and final molecular weight distributions to predict molecular weight, reactor pressure profiles and reactant concentrations, then validated the model with process samples. Using Aspen Technology’s insights Qenos shifted to gradual co‑monomer and hydrogen additions, reached trial targets within three batches, completed other grade trials six months early and saved about $135,000 USD per year ($60,000 from reduced co‑monomer use and $75,000 from less wax by‑product).

Qenos

James Smith

Process Engineer