A formulation that works at 1kg lab scale is not automatically a production-ready one. Run through these four groups before committing a 1000kg bulk batch — each one maps to a variable that behaves differently at scale than it did in the lab.
Lab-scale mixing rarely replicates plant-scale shear forces. If the formulation is shear-sensitive, note it before scale-up.
Mixing efficiency changes with vessel shape and how full it's run — not just agitator specification.
This ratio drops sharply as batch size increases, directly changing heating and cooling rates.
Don't assume the lab's heating curve — measure the plant vessel's real curve before finalizing process timing.
Bulk batches take longer to process end-to-end — extended exposure time can shift outcomes even with an identical recipe.
An intermediate run against real plant parameters catches instability before it happens at full 1000kg volume.
A different water source between lab and plant is a common, easily overlooked cause of scale-up drift.
Decide what "working" means in measurable terms before running the trial — not after looking at the result.
See the detailed root-cause breakdown for scale-up instability, including how we structure the intermediate trial.
