Using process modelling and simulation to support process scale-up and production

Scaling a process from lab to plant brings technical challenges that can impact quality, cost, and performance. Differences in mixing, heat transfer and flow behaviour at larger scales can make it difficult to predict how a process will perform in production.

At CPI, our modelling and simulation experts use digital tools to bridge the gap between lab and manufacturing. By creating digital twins and running virtual experiments, we help identify scale-up risks early, optimise design parameters, and reduce costly trial-and-error work at pilot or plant scale.

How we can help

  • Translate lab-scale results into reliable process data for production.

  • Use computational modelling to test and optimise scale-up strategies.

  • Combine simulation insights with hands-on pilot-scale validation.

Our integrated approach supports faster, safer, and more sustainable scale-up – helping you move from concept to commercial production with confidence.

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