Scale-Up

Good Product Development Practices

- When doing bench experiments, look ahead to how the product will be made in an industrial manufacturing operation
- Make sure ingredients properly measured
- Record order of mixing and all process conditions
- After a prototype is developed, review process and determin how product may be produced on an industrial scale
- Consult with in-house engineers or pilot plant personnel
- Always make plans for scale-up

Importance of order of mixing

- Ingredient functionality altered by milleu at time of addition
- Proteins may precipitate under acid conditions
- Hydrocolloids disperse poorly when there is inadequate moisture available for hydration
- Hydrocolloids are best dispersed if mixed with sugar before addition to a wet mixture
- Sugar and salt affect hydration characteristics of dry ingredients


Scale-up Definition
Production of an identical product at a scale larger than that which was used previously
Process result must be same regardless of the scale of the operation.

Requirements for Successful Scale-up

1. Initial small scale process should simulate the anticipated production process
2. Understand mechanisms which govern the attainment of the desired results
3. Measure quantitatively all processing parameters
4. If possible, use fundamental calculations to appropriately size larger scale equipment