PurposeThe purpose of the work discussed in this paper is to understand, analyse and benchmark the “Packing and Filling” processes within BASF. A benchmarking project is described in detail which aimed to cover sites in different countries that supplied many different variants of finished goods in order to establish best practice and then to generate some options for their implementation.Design/methodology/approachThe project used an adaptation of accepted benchmarking methodology combined with other techniques (such as rich picture generation, and cluster analysis) to maximise the insight generated.FindingsThe findings of the research showed that one of the main factors effecting the process was how third parties were used (e.g. extent and nature of out‐sourcing, and its degree of centralisation).Research limitations/implicationsThe exercise was challenged by the selection of suitably similar benchmarking candidates because the environment was complex and highly varied; the paper explains practical solutions for dealing with this challenge.Practical limitationsStrategic and tactical options are outlined at the end of the paper and will have applicability to other organisations and industries that are looking to find the answers to frequently asked questions about how to successfully implement an internal process benchmarking project in a large complex organisation that has high variety in end products and delivery methods.Originality/valueThe methodology described in this paper is of a proprietary and unique nature. The paper is structured around some key questions commonly asked of benchmarking, and the answers are provided via a real in‐depth case study from BASF that spans 4 sites in 3 countries using 15 different filling lines.

Formation of solids by crystallization and precipitation. Formation of solids from solutions can take place by crystallization or precipitation. The principal factor is the relationship between solubility and supersaturation. In crystallization, the solubility of the crystallising substance is so high that the formation of solids occurs largely in the metastable zone in the immediate vicinity of the solubility limits. Crystal growth and nucleation are functions of supersaturation. If a high supersaturation is required at low substance-specific growth rates for an adequate crystal growth, high nucleation rates and hence small crystals will result. On this basis, the authors present information for the specific design of crystallization processes. In contrast, the solubility of the precipitated product must be very low for precipitation. Direct crystal formation is possible only for substance systems of high solubility. As a rule, however, the precipitated substance is so insoluble that solids are formed via amorphous intermediates. The results of a large number of experiments show the influence of various parameters of the precipitation process on the filtrability of the precipitated product.

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