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Course
PE02Process Scale-Up & Pilot Plant Engineering
Master the science and engineering discipline of taking a process from laboratory scale to full production — safely and reliably.
Duration5 days
FormatIntensive
Level
Advanced
LanguageEnglish
Course overview
[Placeholder — replace with real copy] This five-day intensive course addresses one of the most technically challenging phases in process development: scale-up. Covering mass transfer fundamentals, pilot plant design, reaction engineering considerations, and the critical differences between bench and plant environments, this course equips engineers to lead scale-up projects with confidence. Case studies drawn from pharmaceutical and fine chemicals manufacturing illustrate common failure modes and proven mitigation strategies.
Prerequisites
Delegates should hold a degree in chemical engineering or a closely related discipline and have at least 3 years of process development or production engineering experience.
Who should attend
Target group
Process engineers and R&D engineers transitioning new chemistries from lab/pilot to commercial scale. Pharmaceutical and specialty chemical plant engineers will get the most out of the case material.
What you will learn
- 1Apply dimensionless numbers and similarity criteria to design scale-up strategies
- 2Design and commission a pilot plant for a specified process route
- 3Identify and manage the key risks associated with process scale-up
- 4Develop a technology transfer package suitable for full-scale manufacturing
- 5Evaluate reaction kinetics and mass transfer limitations at pilot scale
- 6Interpret pilot plant data and use it to validate process simulation models
Course modules
Scale-Up Fundamentals and Dimensional Analysis · 7h+
Dimensionless numbers, geometric and dynamic similarity, and the limits of direct scale-up in reactive and multiphase systems.
Reaction Engineering at Scale · 8h+
Kinetics review, heat and mass transfer at pilot scale, reactor selection criteria, and temperature control challenges.
Pilot Plant Design and Safety · 7h+
Layout, instrumentation, utilities, HAZOP of pilot plant P&IDs, and the special safety considerations of small-scale high-hazard operations.
Data Acquisition and Process Characterisation · 6h+
Experimental design, analytical methods, data reconciliation, and using pilot data to update process models.
Technology Transfer and Manufacturing Readiness · 6h+
Technology transfer packages, GMP considerations, scale-up documentation, and readiness reviews.
Case Studies: Real Scale-Up Challenges · 5h+
Group review of documented scale-up failures and successes across pharmaceutical, fine chemicals, and specialty materials industries.
Schedule
Upcoming sessions
Open-enrolment sessions confirmed below. For private in-house delivery on a date that works for your team, request a conversation.
Your instructor
S
Sarah Chen — Process Engineering Lead
View trainer profile →
Bring this course to your team
All Osvard courses are available for in-house delivery at your site or facility. Contact us to discuss dates, customisation, and group pricing.