Chemical Synthesis
Complex Reactions at Commercial Scale
SantoTolling® synthesizes specialty chemicals, intermediates and active ingredients in 19 reactors from 300 to 12,000 gallons. Bring your own route under a toll agreement, or have us source and make the molecule to your spec. Reaction, purification and testing all happen on one 66-acre campus in Spartanburg, South Carolina.
Up to 1.2 Billion Pounds
Annually Produced & Supplied worldwide1
66-Acre Facility
Over a Dozen Specialized Buildings
19 Reactors, 33 Vessels,
67 Tanks & More
Certified Quality
ISO 9001:2015 · ChemStewards · EPA & FIFRA registered · Kosher · Halal
What Is Custom Chemical Synthesis?
Your Molecule, Made by Reaction, Not by Blending
Custom chemical synthesis is the production of a specific molecule to a client's specification by running controlled chemical reactions, rather than blending existing ingredients. It covers everything from a single-step esterification to multi-step routes with gas feeds, pressure and purification.
Most companies outsource synthesis for the same reasons: the reaction needs equipment, conditions or permits they don't have, or the volume doesn't justify building a plant. SantoTolling already runs these reactions for its own product lines and for partners, so your project starts in a facility built for them.
Synthesis connects to the rest of our services. New routes can start in pilot plant & scale-up, and finished molecules can move straight into contract manufacturing, blending and packaging on the same campus.
Reaction Capabilities
Reactions We Run Every Day
SantoTolling handles a wide range of reaction chemistry under one roof. If your route uses one of these, we have the equipment and experience in place.
Esterification & Condensation
- Esterification
- Transesterification
- Condensation
- Amidation
Common uses: esters for lubricants and plasticizers, amides, specialty additives
Alkylation & Alkoxylation
- Alkylation
- Alkoxylation
- Chloromethylation
Common uses: surfactants, emulsifiers, alkylated intermediates
Hydrogenation & Amination
- Hydrogenation
- Reductive amination
- Trimethylamine reactions
- Triethanolamine reactions
Common uses: amines, saturated intermediates, specialty additives
Quaternization
- Methyl chloride quats
- Benzyl chloride quats
Common uses: cationic surfactants, conditioning agents, antimicrobials
Polymerization & Epoxy Chemistry
- Polymerization
- Epichlorohydrin reactions
- Bulk epichlorohydrin
Common uses: functional polymers, thickeners, flocculants, resins
Specialty Reactions & Gases
- Diazotization
- Chlorine, boron trifluoride and anhydrous ammonia
- Anhydrous HCl column
- General synthesis
Common uses: intermediates, active ingredients, specialty chemicals
What We Synthesize
Specialty Chemicals and Intermediates
Additives
Corrosion inhibitors, dispersants, detergents
Surfactants
Anionic, cationic, nonionic, emulsifiers
Polymers
Lubricant Base Fluids
Pesticides
Intermediates
Two Programs. One Campus.
Toll Synthesis or Custom Synthesis
The difference comes down to who owns the route and who buys the raw materials. Both programs use the same reactors, lab and quality systems.
Option 1
Toll Synthesis
Route. Our Reactors. Your IP.
You bring a proven synthetic route and specifications. We run it in our reactors with our utilities, operators and lab, and you keep ownership of the process.
- Your process run as written, at pilot or commercial scale
- Raw materials supplied by you, or sourced by us on request
- Reactor, purification and lab time without capital investment
- Batch records and test results for every run
- IP and formulations stay yours
Best for: companies with a defined route that need reactor capacity, special conditions or a second source.
Option 2
Custom Synthesis
Your Spec. Our Chemistry. A Finished Molecule.
You define the molecule and the specification. Our chemists and engineers work out the production process, source the raw materials and deliver tested product.
- Route and process review with our technical team
- Raw material sourcing and supplier qualification
- Pilot runs before commercial batches
- On-site purification, testing and release
- Packaging, storage and delivery to your schedule
Best for: companies that need a molecule made to spec without managing raw materials or process development.
Need finished formulations instead of a single molecule? See contract chemical manufacturing
Why SantoTolling®
What You Gain When We Run Your Synthesis
Synthesis partners are judged on range, safety and consistency. Here’s what comes with a SantoTolling program.
Broad Reaction Range
From esterification to hydrogenation, quaternization and gas-phase chemistry, most routes fit equipment we already run.
Demanding Conditions
Pressure up to 500 psig, temperatures from -15°C to 300°C and vacuum down to 10 mm Hg in production reactors.
Reaction to Finished Product
Distillation, wiped film evaporation and drying on the same campus, so crude product never ships out for workup.
Identity & Purity Confirmed
A 24/7 lab with NMR, GC-MS, LC-MS and FTIR confirms structure and purity on in-process and finished samples.
Pilot to Commercial Scale
19 reactors from 300 to 12,000 gallons let a route move from pilot batches to full volume without changing sites.
Quality & Compliance
ISO 9001:2015, ChemStewards, EPA and FIFRA registration, and Kosher and Halal certified products.
Side by Side
Toll Synthesis vs. Custom Synthesis
Use this to decide which program fits your project. Many partners start in one and move to the other as volumes grow.
| Option 1Toll Synthesis | Option 2Custom Synthesis | |
|---|---|---|
| Synthetic route | Provided by you | Worked out with our chemists and engineers |
| Process ownership | You keep the process and IP | Your molecule and spec; terms set in your agreement |
| Raw materials | Usually supplied by you | Sourced and qualified by SantoTolling |
| Pilot runs | Optional | Recommended before commercial batches |
| Testing & release | To your methods and spec | Full testing and release by our 24/7 lab |
| Best fit | Defined route, need capacity or conditions | Defined molecule, need a partner to make it |
How It Works
From Target Molecule to Finished Batch
Every synthesis program follows the same five steps, so you know what happens next and who owns it.
Consultation & NDA
We sign a confidentiality agreement, then review the molecule, route and volumes.
Route & Feasibility Review
Chemists and engineers assess the chemistry, hazards, equipment fit and raw materials.
Pilot Batches
First runs in 300-gallon reactors confirm yield, purity and safe operating limits.
Commercial Synthesis
Production in reactors up to 12,000 gallons with in-process testing and batch records.
Purify, Test & Ship
Workup, release testing and packaging in drums, totes or bulk.
Equipment Behind Every Reaction
Reactors, Purification and Analysis on One Campus
Synthesis programs run on the same infrastructure that supports SantoLubes® Manufacturing’s own product lines.
- Stainless steel reactors, 300–12,000 gal; glass-lined, 300–4,000 gal
- Venturi mixers for gas/liquid reactions and an anhydrous HCl column
- Distillation columns with 12, 15 and 30 trays
- Wiped film evaporator, aqueous spray dryers and rotary vacuum dryer
- Dispersion mixers, grinders and homogenizers
- Karl Fischer, titration, viscosity, surface tension and particle size testing
500 psig
Max pressure
-15° to 300°C
Temperature range
10 mm Hg
Vacuum
SantoTolling provides other useful features:
Reactor Fleet
19 glass-lined and stainless steel reactors.
Purification
Distillation, evaporation and drying on site.
24/7 Analytical Lab
NMR, GC-MS, LC-MS, FTIR and more.
Industries We Serve
Synthesis for Demanding Markets
Agriculture
Pesticide actives, adjuvants and crop protection blends made under EPA and FIFRA registration.
Aviation
Aerospace-grade fluids and specialty intermediates produced under strict quality control.
Automotive
Specialty fluids, additives and coatings for OEM and aftermarket supply chains.
Oil & Gas
Corrosion inhibitors, surfactants and specialty additives for upstream and midstream.
FAQ
Straight answers to what buyers ask us most before a synthesis project.
What is custom chemical synthesis?
Custom chemical synthesis is the production of a specific molecule to a client's specification by running controlled chemical reactions, rather than blending existing ingredients. At SantoTolling, synthesis runs in glass-lined and stainless steel reactors from 300 to 12,000 gallons on our campus in Spartanburg, South Carolina, with every batch tested in our 24/7 analytical lab.
What is the difference between toll synthesis and custom synthesis?
In toll synthesis, the client supplies the synthetic route and specifications, often provides some or all of the raw materials, and keeps ownership of the process. In custom synthesis, SantoTolling sources the raw materials, works out the production process with the client and delivers finished product to spec. SantoTolling offers both.
What chemical reactions can SantoTolling run?
SantoTolling runs alkoxylation, alkylation, amidation, condensation, esterification, transesterification, polymerization, hydrogenation, reductive amination, diazotization, chloromethylation and quaternization with methyl and benzyl chloride. The site also handles epichlorohydrin reactions including bulk epichlorohydrin, trimethylamine and triethanolamine reactions, and processes using boron trifluoride, chlorine and anhydrous ammonia gases.
What reactor sizes and operating conditions are available for synthesis?
SantoTolling operates stainless steel reactors from 300 to 12,000 gallons and glass-lined reactors from 300 to 4,000 gallons, part of a fleet of 19 reactors, 33 vessels and 67 tanks. Reactions can run at pressures up to 500 psig, temperatures from -15°C to 300°C and vacuum down to 10 mm Hg.
Can SantoTolling purify the product after synthesis?
Yes. Purification and finishing equipment on the same campus includes distillation columns with 12, 15 and 30 trays, a wiped film evaporator, aqueous spray dryers and a rotary vacuum dryer, so crude product does not need to ship to another site for workup.
How does SantoTolling confirm product identity and purity?
SantoTolling's 24/7 analytical laboratory tests raw materials, in-process samples and finished product using GC, GC-MS, LC-MS, NMR, FTIR and UV-Vis, along with Karl Fischer water analysis, potentiometric and wet titration, viscosity and surface tension measurement, and particle size analysis.
Does SantoTolling synthesize agricultural active ingredients?
Yes. SantoTolling is EPA and FIFRA registered and manufactures pesticide active ingredients, intermediates and adjuvants for crop protection products, under ISO 9001:2015 quality systems.
How do I start a chemical synthesis project with SantoTolling?
Start with a free consultation by calling (864) 585-3661, emailing sales@santolubes.com or submitting the project form on this page. Share the target molecule or reaction, your current route and scale, target volume and any safety data sheets, and an engineer will follow up to scope the project.
