Scale-Up Readiness Checklist
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.
01 · Mixing & Shear
Compare agitator type and speed, lab vs. plant
Lab-scale mixing rarely replicates plant-scale shear forces. If the formulation is shear-sensitive, note it before scale-up.
Confirm vessel geometry and fill ratio at plant scale
Mixing efficiency changes with vessel shape and how full it's run — not just agitator specification.
02 · Heat Transfer
Calculate surface-area-to-volume ratio at bulk scale
This ratio drops sharply as batch size increases, directly changing heating and cooling rates.
Measure actual heat-up and cool-down time at plant scale
Don't assume the lab's heating curve — measure the plant vessel's real curve before finalizing process timing.
03 · Reaction & Dwell Time
Recalculate reaction/dwell time for bulk batch duration
Bulk batches take longer to process end-to-end — extended exposure time can shift outcomes even with an identical recipe.
Define an intermediate trial scale between lab and full bulk
An intermediate run against real plant parameters catches instability before it happens at full 1000kg volume.
04 · Water & Success Criteria
Compare water hardness and mineral content, lab vs. plant source
A different water source between lab and plant is a common, easily overlooked cause of scale-up drift.
Set a defined success criterion before the trial starts
Decide what "working" means in measurable terms before running the trial — not after looking at the result.
Already seeing instability at bulk scale?
See the detailed root-cause breakdown for scale-up instability, including how we structure the intermediate trial.