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Once a candidate API is identified, the synthesis process begins. This process typically involves multiple chemical reactions to transform raw materials into the desired compound. Depending on the complexity of the API, the synthesis may require a series of steps, including reaction conditions like temperature and pressure, the use of catalysts, and solvent selection. The aim is to achieve high yield and purity while minimizing by-products. Advanced technologies such as continuous flow chemistry and green chemistry practices are increasingly being adopted to enhance efficiency and reduce environmental impact.

The choice of antioxidant is crucial and can depend on several factors, including the type of plastic material, processing conditions, and the intended application. For instance, polyolefins, which are commonly used in various applications, often benefit from hindered phenolic antioxidants due to their thermal stability and compatibility with the substrate. Meanwhile, engineering plastics like polycarbonate may require different types of antioxidants that can provide protection at elevated temperatures.

Following the successful completion of pilot manufacturing and quality assurance checks, companies move on to full-scale production. This stage involves the extensive use of reactors, filters, and other industrial equipment to produce the API in large quantities. Everything from raw material sourcing to waste management becomes critical to ensuring not only the quality of the APIs but also the safety and compliance with Good Manufacturing Practices (GMP).

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