Secrets of Batch Process Scale-Up

Date: 08 May - 12 May 2023

Location: Online Platform

Tutors: Francis X. McConville

We are delighted to still be able to offer this course On Line,  it will be divided into five sections, over five days – please see the timings and dates below which are set in UK time zone:

Monday, May 8th | 1.30 pm – 5.30 pm BST
Tuesday, May 9th | 1.30 pm – 4.30 pm BST
Wednesday, May 10th | 1.30 pm – 5.30 pm BST
Thursday, May 11th | 1.30 pm – 4.30 pm BST
Friday, May 12th | 1.30 pm – 5.30 pm BST

This course is designed for those with limited or no pilot plant or scale-up experience, provides a comprehensive overview of the most common problems experienced during the scale up of laboratory batch processes, and ways to avoid or mitigate them. The difference between laboratory scale techniques and how the major unit operations are carried out in the pilot plant is a key focus of the course. Thus, along the way attendees will examine the many issues associated with raw material handling, conducting synthetic reactions, reaction workup, product crystallization, isolation and drying at the pilot plant or commercial scale.

The course also explores some important engineering concepts such as batch mixing, heat transfer, mass transfer, fluid flow and the influence of these factors on the success of large scale chemical operations. With an awareness of these phenomena, the laboratory researcher will have a better understanding of the types of experiments that should be conducted and the types of data that should be collected to ensure a more successful scale-up. Numerous examples and case histories are presented to reinforce the course material, and class exercises provide an opportunity to put some of the lessons into practice. Heavy emphasis is placed on process safety.


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Course outline

Process Design for Scale-Up
Process development strategies
Importance of engineering in PDsScale-Up – An Overview
Role of the Pilot Plant
Overview of scale-up issues
Technology transfer issuesBatch Reactors
Typical plant operations and equipment
Characteristics of batch operationsRaw Materials
Raw material and route selection
Large-scale charging methods and issuesTemperature Control
Large scale temperature control
Heat transfer in batch reactors
Controlling exothermic reactionsFollowing Reaction Progress
Reaction endpoint determination
Sampling methods / issues
On-line analytical techniques
Agitation and Mixing
Large scale mixing equipment
Mixing limited reaction
Mixing scale-up / scale-down

Quench & Work-Up
Liquid-liquid extractions
Phase continuity issues and emulsions
Distillation & Stripping
Differential distillation
Azeotropes and solvent exchange
Crystallization and Precipitation
Basic principles / yield estimation
Controlling supersaturation
Scale-up issues
Product Isolation and Drying
Large-scale solid-liquid separations
Filtration and drying equipment
Filtration and drying modelling
Process Hazards and Safety Assessment
Common hazards in large-scale processing
Process hazard assessments and evaluations


Benefits of attending

On completion of this course you will be able to:

  • Assess the safety and scalability of new processes
  • Identify process operations that may be problematic on scale-up
  • Design processes that will minimize or avoid common scale-up issues
  • Better understand heat transfer and mixing requirements for scale-up
  • Develop more robust crystallization, isolation and drying processes

Who should attend

This course has been designed for chemists, engineers, technicians and managers in the fine chemical and pharmaceutical industries with limited pilot plant experience who wish to learn more about the potential pitfalls of process scale-up and ways to avoid them. Attendees will come away from the course more knowledgeable about common scale-up problems and better equipped to prepare for and deal with them. The course complements the more chemistry-focused Scientific Update course “Chemical Development and Scale-Up in the Fine Chemical and Pharmaceutical Industries”.

What's Included

The course fee includes:

  • Link to watch all five live sessions
  • Electronic version of the course manual*
  • Course certificate

For this on line course, there will be no recordings available and *the e reader manual is NOT printable or downloadable (due to copyright).  If you prefer a hard copy of the manual you will have the opportunity of purchasing a professionally printed hard copy during the booking process.  You can also purchase a copy of the Pilot Plant book (at a special price).

Hard copy of Manual = £120.00

Pilot Plant book = £90.00 (normally £140.00)

** Please note each session is not recorded or shared after the course


Online Hovione Delegate

Amazing course with a wise speaker. Thank you!

Online Pfizer Delegate

I thoroughly enjoyed Fran’s class. If you have the opportunity, do not hesitate to take it!

Online Pfizer Delegate

Thank you for a wonderful experience and introduction to process chemistry/scaling up!

Online ThermoFisher Scientific Delegate

This course was well presented with engaging delivery. Gave a broad but thorough introduction to a number of very important topics in relation to scale-up from laboratory to pilot/commercial scale. Overall very useful for any lab chemist in an industrial setting!

Online Bachem Delegate

The course gives a good overview of the topic process upscale and helps to understand where potential problems might occur and why.

Online Institute for Chemical and Engineering Sciences Delegate

This course is very useful for budding process chemists trying to learn how to translate their work from the laboratories to the pilot plant scale.
Also, the incorporation of examples and case studies were very useful.

Online Johnson Matthey Delegate

This course included all unit operations that we are currently set up in our plant. All unit ops touch in this course and very helpful for us keep that in mind during the scale-up.

Online Kemitek Delegate

Excellent course, a must have for chemists.


Face-to-face Event Enquiry

Secrets of Batch Process Scale-Up

This course is available as a face-to-face event upon request. Please provide your details and we will get back to you with further information.

Face-To-Face Training Session

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In-House Event Enquiry

Secrets of Batch Process Scale-Up

This course is available as an In-House event upon request. Please provide your details and we will get back to you with further information.

In-House Training Session

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