Question 1

Does batch scaling always work linearly?

Accepted Answer

Linear scaling works for simple mixtures and non-reactive formulations. For chemical reactions, heat and mass transfer do not scale linearly — surface-to-volume ratio decreases with size, affecting cooling rates and mixing. Large scale-ups often require process engineering adjustments beyond simple proportional scaling.

Question 2

What is a typical pilot-to-production scale factor?

Accepted Answer

Pilot-plant batches are typically 10-100× lab scale (e.g., 1-10 kg from 100 g lab batches). Production scale-up from pilot is often another 10-50×. A conservative approach uses multiple intermediate steps (lab → mini-pilot → pilot → production) to identify and resolve scaling issues early.