1. SCALE-UP
• Definition
– Act of using results obtained from laboratory
studies for designing a prototype and a pilot
plant process;construction a pilot plant and
using pilot plant data for designing and
constructing a full scale plant or modifying an
existing plant

2. Problems in Scale up an Food
Production Processes
• Fundamental knowledge of chemical and
physical interactions among complex
ingredients is either scarce or non-existent
• There is usually a lack of data of physical
properties for complex food formulations
(specific heat capacities, thermal
conductivities, phase relationship, rheology,
etc)

3. Steps in Scale-Up
• Define product economics based on projected market size and
competitive selling and provide guidance for allowable manufacturing
costs
• Conduct laboratory studies and scale-up planning at the same time
• Define key rate-controlling steps in the proposed process
• Conduct preliminary larger-than-laboratory studies with equipment to
be used in rate-controlling step to aid in plant design
• Design and construct a pilot plant including provisions for process
and environmental controls, cleaning and sanitizing systems,
packaging and waste handling systems, and meeting regulatory agency
requirements
• Evaluate pilot plant results (product and process) including process
economics to make any corrections and a decision on whether or not
to proceed with a full scale plant development

4. Why conduct Pilot Plant Studies?
• A pilot plant allows investigation of a product and
process on an intermediate scale before large
amounts of money are committed to full-scale
production
• It is usually not possible to predict the effects of a
many-fold increase in scale
• It is not possible to design a large complex food
processing plant from laboratory data alone with
any degree of success

5. A pilot plant can be used for
• Evaluating the results of laboratory studies and making product and
process corrections and improvements
• Producing small quantities of product for sensory, chemical,
microbiological evaluations, limited market testing or furnishing
samples to potential customers, shelf-live and storage stability studies
• Determining possible salable by-products or waste stream requiring
treatment before discharge
• Providing data that can be used in making a decision on whether or not
to proceed to a full-scale production process; and in the case of a
positive decision, designing and constructing a full-size plant or
modifying an existing plant

6. Considerations in pilot plant development
• Kind and size – depends on goals; evaluating product and
process; producing samples of product for evaluation;
market testing or furnishing to potential customers
• Location: near R&D facility? At an existing plant? Close
liaison between R&D and pilot plant staff is essential
• Labor requirements and costs: engineering staff, skilled
operations and maintenance staff- pilot plant costs may
exceed those of usual plant production costs. The pilot
plant may be used for training personnel for a full- scale
plant

7. SIMILITUDES IN SCALE-UP
• 4 DIMENSIONS – FORCE, MASS, DISTANCE AND LENGTH
– LACK OF DIFFERENTIAL EQUATIONS DURING PILOT PLANT
TRIALS LIMITS USEFULLNESS
• DYNAMIC – EQUALITY BETWEEN DIMENSIONLESS
NUMBERS
– NOT ALWAYS POSSIBLE TO ACHIED DYNAMIC SIMILARITY
BETWEEN SCALES. DIFFERENCES SUCH AS VORTEXING AND
SURFACE TENSION CAN EFFECT RESULTS.
• CHEMICAL- OFTEN IMPOSSIBLE TO DETERMININE RATE
LIMITING REACTIONS IN FOOD SYSTEM
– DIFFUSION AND TEMPERATURE CAN BE IMPORTANT AND NOT
ALWAYS COMPARABLE AT DIFFERENT SCALES

8. EXAMPLE – YEAST FERMENTATON
• DEFINE DESIRED RESULTS
– PRODUCTION SIZE
– FERMENTER SIZE
– RAW MATERIALS
– SOLIDES AFTER CENTRIFUGING
• LAB SCALE DATA AVAILABLE
– EVALUATION INFORMATION AT HAND
• SCALE UP REQUIRED FOR
– HOLDING TANKS
– FERMENTER FOR SEED INOCULUM
– 4 SCALES TO FULL PRODUCTION OF FERMENTERS, CENTRIGUGES,
FILTRATION AND DRYING

9. Yeast Scale-up Example
Production goal: 7200 kg (dw)/14 hr. run
Fermenter-150 m3 (120 m3 working volume),
14 h run., fed batch operation
Solids after centrifugation, filter – pressing and
drying, 96%

10. Yeast Scale-up Example
Production goal: 7200 kg (dw)/14 h run
Fermenter-150 m3 (120 m3 working volume),
14 h run., fed batch operation
Solids after centrifugation, filter – pressing and
drying, 96%

11. Yeast Scale-up Example
• Laboratory Scale Data:
Fermenter, 15 L (12 L working volume).
H/D 2:1, t = 30C., pH 4.5, heat output 3-4.4
kcal/ g yeast solids, dissolved O2 7 ppm.
Specific growth rate, 0.2/h, yield 0.55kg/kg
fermentable sugars, cell conc. 0.65 g (dw)/L
• Pilot plant fermenter, 150 L