From Lab to Plant: Reliable Scale-Up and Performance Guarantees with EvapCare™

Introduction

Scaling up a film evaporation process from laboratory trials to full-scale industrial production is a critical step for any manufacturer. Uncertainties in scale-up can lead to costly delays, inconsistent product quality, and operational setbacks. Sulzer’s EvapCare technology is designed to eliminate these risks by offering a comprehensive approach—combining pilot testing, proven engineering, and robust process guarantees to ensure your industrial success.

The Challenges of Scaling Up Evaporation Processes

Transitioning from lab to plant involves more than simply increasing equipment size. Differences in hydrodynamics, heat transfer, and product behavior can affect performance at larger scales. For heat-sensitive or viscous products, these challenges are even greater. Without proper validation and expertise, scale-up can result in unexpected bottlenecks, product losses, or equipment issues.

Sulzer’s Approach: From Feasibility Study to Guaranteed Performance

Feasibility Studies and Laboratory Trials

Sulzer’s process begins with feasibility studies and laboratory-scale trials. These tests allow you to:

• Examine flow and wetting characteristics

• Evaluate and optimize the type of evaporator (falling film, wiped film, or short path)

• Determine achievable concentrations and yields, often down to ppm levels

  
  

Pilot Testing and Process Validation

Pilot trials are conducted in Sulzer’s state-of-the-art test centers or with rental equipment at your own site. This hands-on approach ensures:

• Realistic process validation using your actual feedstocks

• Accurate data on operating pressure, flow rates, and product behavior

• Optimization of critical parameters such as recirculation ratio and stripping gas

  
  

Reliable Scale-Up and Engineering

Based on pilot results, Sulzer’s experts design and size your industrial evaporator using proven scale-up methodologies.

Detailed engineering covers:

• Mechanical design and equipment selection

• Skid layout, piping, automation, and safety (HAZOP)

• Fabrication, testing, and quality assurance

  
  

Performance Guarantees

Sulzer’s extensive experience and reference base enable them to offer process guarantees ensuring your plant delivers the specified throughput, purity, and yield. This minimizes risk and provides peace of mind throughout your project.

Customer Success Stories

Case 1: Pharmaceutical Scale-Up

A pharmaceutical manufacturer needed to scale up the purification of a heat-sensitive API. After successful pilot trials with a wiped film evaporator, Sulzer delivered a full-scale system with guaranteed performance, enabling rapid market entry.

Case 2: Food Ingredient Production

A food company required concentration of a natural flavor at industrial scale. Lab and pilot tests identified the optimal falling film evaporator configuration, resulting in high product quality and reliable operation from day one.

Comprehensive Support Throughout the Project Lifecycle

Sulzer’s commitment doesn’t end at commissioning. They provide:

• Installation supervision and operator training

• Maintenance, troubleshooting, and debottlenecking support

• Ongoing process optimization and plant upgrades

  
  

Conclusion

Sulzer’s EvapCare technology offers a proven, risk-free path from laboratory concept to industrial reality. With expert support, pilot testing, and performance guarantees, you can scale up your evaporation process with confidence ensuring consistent product quality and operational excellence.

Contact Us

Ready to scale up your process with confidence?

Contact Sulzer today for pilot trials, expert engineering, and guaranteed results with EvapCare.