From Data to Investment: How Validation Trials Support Reliable Process Scale-Up
- cemnar0
- Jul 29
- 2 min read
Introduction: Turning Pilot Data into Investment Confidence
Scaling up a chemical or separation process from concept to full industrial operation requires more than theoretical design it demands reliable, validated data that stakeholders can trust. Sulzer’s lab and pilot services provide this critical bridge by generating comprehensive performance data through pilot validation trials, thereby enabling confident investment decisions and minimizing technical and financial risks.
With decades of experience and over 1,000 pilot trials completed, Sulzer’s IntecH centers combine advanced pilot equipment and expert analysis to deliver actionable insights that accelerate the route to commercialization.
The Role of Sulzer’s Lab and Pilot Services in Scale-Up
Generating Comprehensive Data Sets
Sulzer’s pilot services enable precise measurement of key process parameters, including:
Mass and energy balances: Validating feed conversion rates and energy consumption
Product quality and purity: Ensuring consistent compliance with specifications
Process robustness: Assessing sensitivity to feed variations and operating conditions
Scale-up factors: Providing validated extrapolation data from pilot to full scale
This technical data is essential to inform engineering design, capital budgeting, and operational planning.
Reducing Technical and Financial Risk
Early pilot validation helps identify unforeseen challenges such as fouling, foaming, or impurities that can jeopardize a project. By addressing these issues upfront with Sulzer’s lab and pilot services, companies can:
Avoid costly design modifications and downtime post-commissioning
Provide credible evidence for financing, permitting, and stakeholder assurance
Optimize process configurations for maximum efficiency and yield
Case Study: Accelerating Sustainable Process Scale-Up
A recent project supported by Sulzer’s pilot services showcased how validated pilot data accelerated scale-up of a bio-based purification process. Using lab and pilot trials at the Allschwil IntecH center, detailed performance and impurity removal data enabled the design of a low-energy, high-yield industrial plant producing high-purity bio-derived chemicals demonstrating the tangible impact of validated pilot data on project success.
Workflow: From Pilot Testing to Commercial Implementation
Pilot Trial Planning: Defining test scope, required data, and success criteria in close collaboration with the customer.
Lab and Pilot Execution: Running customized pilot experiments using customer feeds under closely monitored conditions to capture comprehensive datasets.
Data Analysis and Reporting: Transforming raw data into actionable insights through advanced analytics, including purity assessments, mass/energy balances, and performance trends.
Decision Support: Delivering detailed reports to aid technical, financial, and regulatory decision-making—facilitating go/no-go calls and engineering design.
Scale-Up Engineering: Leveraging pilot-proven data to optimize full-scale plant design, minimize commissioning risks, and ensure project timelines are met.
Why Partner with Sulzer’s Lab and Pilot Services?
Unmatched Expertise: Extensive experience with complex separation processes and challenging feedstocks.
Advanced Facilities: State-of-the-art pilot plants and analytical labs located in Switzerland and Singapore.
Comprehensive Support: End-to-end service from early lab testing to pilot trials and scale-up engineering support.
Proven Track Record: Backing over 1,000 pilot tests worldwide, supporting multiple industrial sectors.
Conclusion: Investing with Confidence Through Sulzer’s Pilot Validation
Capital-intensive chemical plant projects need validated, reliable data to guide investment. Sulzer’s lab and pilot services provide precisely that—transforming pilot-scale results into solid engineering foundations that reduce risks, optimize process design, and accelerate commercialization.
Ready to leverage Sulzer’s lab and pilot expertise to advance your process scale-up?
Contact our team today to discuss your project and discover how tailored validation trials can secure your path to successful investment and operation.
