Pilot Plant & Scale-Up
Bridging laboratory development and commercial manufacturing. Capot provides pilot verification and scale-up support using 100–500 L pilot reactors to validate laboratory processes and assess key factors such as mixing, heat transfer, dosing, work-up and equipment fit as scale changes, preparing the process for commercial production.
Explore our pilot & scale-up capabilities →Pilot & Scale-Up Execution
Validate laboratory-developed processes under larger-scale operating conditions and confirm reproducibility and scale-up feasibility.
Assess how mixing performance and mass-transfer behaviour change during scale-up.
Evaluate reaction heat, cooling requirements and temperature control capability under pilot conditions.
Optimise dosing sequence, rate and material input to preserve reaction consistency and process safety.
Pilot verification of work-up operations including extraction, washing, filtration, crystallisation, centrifugation and drying.
Refine process parameters based on pilot results to prepare for commercial transfer.
Route Evaluation
Process Optimisation
Scale-Up Strategy
Technology Transfer
From Laboratory to Pilot Scale
Laboratory Process Review
Assess the developed route, process parameters, raw materials and technical requirements.
Scale-Up Preparation
Identify scale-up-related risks and prepare operating parameters, equipment and control strategy.
Pilot Verification
Validate the reaction, work-up, isolation and process consistency at pilot scale.
Commercial Transfer
Transfer validated process documentation and operating requirements into commercial manufacturing.
Key Scale-Up Considerations
Reaction Kinetics
Assess how reaction behaviour changes as batch size increases.
Heat Removal
Evaluate reaction exotherm and cooling capability.
Mixing Efficiency
Assess mixing performance and concentration gradients at larger scale.
Dosing Rate
Control addition rate to maintain reaction performance and safety.
Gas–Liquid Mass Transfer
Evaluate the impact of gas–liquid mass transfer on processes where it is relevant.
Crystallisation Behaviour
Assess nucleation, crystal growth, filtration and product isolation performance.
Equipment Fit
Select equipment and operating configuration suitable for pilot scale.
Process Repeatability
Verify that the process remains stable and repeatable at larger scale.
Technology Transfer to Production
Process Documentation
Prepare process parameters, operating requirements and key technical documentation.
Production Readiness
Confirm equipment suitability, material requirements and operating conditions before production.
First-Batch Support
Provide technical support during early production batches to enable a smooth transfer.
Feedback & Optimisation
Further refine process parameters where needed based on production feedback.
Project Support
Technical Evaluation
Assess process maturity, scale-up requirements and technical risk before pilot execution.
Project Communication
Maintain clear project milestones, technical updates and communication during pilot scale-up.
Quality Support
Provide analytical testing and quality documentation support during pilot and production transfer.
Ready to advance process scale-up?
If you are optimising an existing route, evaluating scale-up risk or preparing to enter pilot stage, Capot can support process development, scale-up assessment and technology transfer.
Discuss your process project →