Mr Aaron Sarafinas

Sarafinas Process & Mixing Consulting LLC

Aaron Sarafinas



  • Consulting, Individual

Job Function

  • Consulting (in private practice)


I have established myself as an expert in bridging between the R&D lab and commercial production units. I specialize in process development, especially on the impact of mixing technology, with decades of industrial experience in both technical and leadership roles. Throughout my career, I have helped internal clients and external customers realize that
-- "good mixing" is impossible without the proper process context, and
-- "using the right tools in the right way at the right time” is the efficient way to build process understanding and achieve commercial success.

Two things have been critical to me throughout my career:
-- to be at the forefront of creating and improving best practices around process development and mixing,
-- to raise the working-level knowledge of “process practitioners” on how best to apply mixing and process technology to achieve commercial success.

I started Sarafinas Process & Mixing Consulting LLC to enable clients to achieve faster process development and scaling and leverage advantaged mixing technology.

My technical specialty areas include
  • Chemical Process Development and Scale-up
  • Mixing Technology (especially multi-phase mixing and reaction systems, including polymerizations, often evaluating “will this mixer deliver the desired process results?”)
  • Developing and delivering process technology training
  • Technology leadership and facilitating "Generate & Reduce Options" activities to create innovative solutions to technical problems
Prior to starting Sarafinas Process & Mixing Consulting LLC, I worked for Dow / Rohm and Haas for over 35 years.  In my most recent assignment with The Dow Chemical Company, I served as the Process Development Global Subject Matter Expert. As a technical leader in the global Advanced Polymers Process Technology area, I advanced conceptual, experimental, and computational methods, enabling faster and more reliable development, scale-up, troubleshooting, and customer product introduction.

Prior to Dow acquiring Rohm and Haas in 2009, I was a Distinguished Engineer with Rohm and Haas Company where I consulted for all internal businesses on process development, mixing, scale-up, reaction systems, and cost estimation / financial analysis.   I developed ways to streamline early process development and scale-up. I facilitated Brainstorm/Peer Reviews and other ideation processes to generate innovative solutions to technical problems.  Further, I taught Scale-Up and Scale-Down in company Reaction Systems Course. I also served as the company liaison to BHR Group’s Fluid Mixing Processes (FMP) Consortium and University of Maryland High Shear Mixing Research Program.


Villanova University
Villanova, Pennsylvania, United States
Chemical Engineering
To 1988

Northeastern University
Boston, Massachusetts, United States
Chemical Engineering
To 1982


  • AIChE Senior Member
  • Delaware Valley Local Section
  • North American Mixing Forum
  • Process Development Division
  • Virtual Local Section

Current Entity Roles

  • Virtual Local Section (Vice Chair)

Online contributions