The back-off methodology has been extensively developed and refined in the last 20 years and offers a systematic tool for solving the simultaneous design and control problem. Previous work has been based on linear process and control models that ensure quick determination of the optimal solution at the expense of potential loss in the accuracy due to nonlinear process characteristics. In this work a new formulation is proposed where use is made of a nonlinear process model that ensures improved accuracy and also offers an improved opportunity for the simultaneous consideration of process design and process control. Two case studies are studied in detail and demonstrate the advantages of the new formulation. (C) 2016 American Institute of Chemical Engineers