{"id":11474,"date":"2026-08-26T09:15:47","date_gmt":"2026-08-26T07:15:47","guid":{"rendered":"https:\/\/www.three-tec.ch\/?page_id=11474"},"modified":"2026-09-04T11:38:43","modified_gmt":"2026-09-04T09:38:43","slug":"scale-up","status":"publish","type":"page","link":"https:\/\/www.three-tec.ch\/en\/know-how\/scale-up\/","title":{"rendered":"Scale-up: The Path from the Lab to Production"},"content":{"rendered":"

Scale-up<\/h1>\t\t\t\t\t\n\t\t\tThe Path from the Lab to Production\t\t\n\t

\n\t\t\t\tWhat does \"scale-up\" mean?\n\t\t\t<\/h2>\n\t\t\t\u00a0Scale-up refers to the transfer of a process successfully developed in the laboratory to larger-scale equipment and ultimately to industrial production\u2014while maintaining consistent product quality and reproducibility.\u00a0Three-Tec is one of the few suppliers worldwide to manufacture laboratory equipment with screw diameters starting at 5 mm. Due to their low material consumption, these devices are ideal for process development and deliver results suitable for scale-up. Learn more about our Feeding systems<\/a> and Extruders<\/a>.\t\n\t

\n\t\t\t\tWhy is scaling up important?\n\t\t\t<\/h2>\n\t\t\tMany processes initially work only under laboratory conditions. For commercial production, they must be scaled up to higher throughputs in a reproducible manner.\t\n\t

\n\t\t\t\tTest laboratory\n\t\t\t<\/h2>\n\t\t\t

At Three-Tec\u2019s testing and application lab, existing and new processes can be developed and optimized under realistic conditions before being transferred to production. Learn more on our page about the Test laboratory<\/a> or in the article Tests with your original products in our laboratory<\/a>.<\/p>\t\n\t

\n\t\t\t\tFrequently Asked Questions\n\t\t\t<\/h2>\n\t\t\t

What steps are involved in a typical scale-up process?<\/strong>A successful scale-up typically involves six steps: a laboratory feasibility study, formulation development and optimization, definition of critical process parameters, testing on pilot plants, transfer to production facilities, and final process validation.\u00a0Which process parameters are particularly critical during scale-up?<\/strong>The most important factors include residence time, shear rate, temperature profile, material throughput, mixing intensity, and dosing accuracy. Even small deviations in these parameters can affect product quality. Only documented processes can be reliably replicated.\u00a0Why is precise dosing important for a successful scale-up?<\/strong>A stable and consistent supply of raw materials is essential for reliably transferring process results from the laboratory to larger-scale facilities.\u00a0Why do modular systems make scale-up easier?<\/strong>If laboratory equipment and production facilities have similar screw geometries and comparable process conditions, a process developed in the laboratory can be transferred to production much more easily and reliably.\u00a0<\/p>\t\n\t

\n\t\t\t\tOther Topics\n\t\t\t<\/h2>\n\t\t\t\t\t