Screening & Scaling up
Lab-, Pilot- & Industrial-Scale
Successful scale-up: from screening to production
Rely on more than 40 years of experience in industrial-scale photoreactor manufacturing.
A successful scale-up process is essential for photochemical production in order to specifically test and optimize each step. This involves checking whether the planned photochemical process works under real conditions and what equipment is required. From laboratory scale to industrial application, the parameters are adjusted step by step. In the pilot phase, the process is further refined and initial product quantities are produced on a smaller scale. This phase makes it possible to evaluate process stability and efficiency before large-scale production begins. Careful scale-up minimizes risks and ensures the economic viability of the process. Our photoreactors support this transition with customized solutions for different production stages. In this way, the development of innovative photochemical processes is driven forward efficiently and safely.
Scale-up: From the idea to industrial production.
A successful scale-up process is essential for testing and optimizing photochemical processes under real conditions. Our customized photoreactors assist you from the laboratory phase to industrial application – for maximum efficiency and process reliability.
Ready for the next step?
STEP 1
Wavelength screening photoreactors
When carrying out photochemical reactions, it is of fundamental importance to analyze which wavelength is absorbed by the reaction mixture and is ultimately photochemically relevant.
Furthermore, it is important to understand the influence of temperature on the process. Some reactions involve a multiphase reaction mixture, such as photocatalysis, which requires uniform mixing. All basic investigations have one thing in common – the amount of available starting material during screening is limited for reasons of product availability or material cost, so a small volume of the product from 0.5 – 8 ml is of great advantage.
All these aspects have led us to develop a unique and innovative multi-vial screening photoreactor, which is the only product available on the market that is able to solve all tasks in an excellent way – the PX 9 Parallel Screening Photoreactor.
Step 2
Lab size photoreactors
Three varieties of Modular Photochemical Development Systems (MPDS®) are employed within the laboratory environment. The MPDS®BASIC system is utilised to conduct preliminary feasibility assessments aimed at grasping essential photochemical concepts, choosing the most suitable lamps, and showcasing basic viability with minimal product quantities, prior to advancing to the optimisation and process development stage and scaling up to an industrial level. The MPDS®EVO and MPDS®PRO systems are specifically tailored for executing process development and gathering all pertinent data necessary for effective scale-up. The primary distinction between the EVO and PRO series resides in the enhanced chemical resistance classification, as well as the temperature and pressure range associated with the PRO series.
STEP 3
Pilot size photoreactors
Pilot photoreactor systems are designed to ensure a secure scaling process during intricate synthesis phases, with the objective of measuring the space-time yield and output of larger industrial photoreactors. This information allows for more accurate analyses of CAPEX and OPEX, as well as a better understanding of hydrodynamic effects. Typically, pilot photoreactors are flame-resistant, certified, and compliant with GMP standards, enabling clients to produce the necessary batch sizes and samples.
Step 4
Industrial size photoreactors
Commercially available photoreactors of industrial scale are tailor-made for each unique process. Nonetheless, due to the extensive use of standardised components, like immersion lamps that come with flameproof certification, this undertaking is straightforward and can be executed swiftly and dependably, delivering the necessary power density for remarkably efficient production. Some industrial-scale photoreactions are scaled-up by numbering-up, depending on the type of photoreactor used and the amount of product required.
Our engineers develop photoreactors and immersion lamp systems for demanding industrial environments, supporting radiation sources from 10 kW to 60 kW. We offer ATEX-certified immersion lamps up to 40 kW for explosion-risk areas. A sophisticated control system ensures safe operation, monitoring, and fault analysis from the control room.
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