Pilot Scale Manufacturing

Our pilot plant is designed to bridge the gap between laboratory-scale processes and commercial production, focusing on scaling up chemical processes to volumes of 20L to 300L. Here, we carefully examine all relevant aspects, including safety, feasibility, product quality, and critical operating parameters. This thorough evaluation ensures that we gather essential data for further scaling and cost estimation.

InnoSyn pilot plant offers scalable solutions with flexible systems in process optimization and continuous manufacturing.
InnoSyn pilot plant offers scalable solutions with flexible systems in process optimization and continuous manufacturing.
InnoSyn pilot plant offers scalable solutions with flexible systems in process optimization and continuous manufacturing.
InnoSyn pilot plant offers scalable solutions with flexible systems in process optimization and continuous manufacturing.

If you are looking to produce kilograms of a representative product for market purposes or need a specific chemical manufactured, our pilot plant is fully equipped to meet your requirements. We offer a flexible, non-GMP facility that can handle various technologies, including flow chemistry, photochemistry, chemo- and biocatalytic reactions and continuous downstream processing. Our expertise includes catalytic hydrogenations, oxidations, enzymatic and asymmetric transformations, making us well-suited for your project. 

Let us assist you in transforming your chemical product ideas into tangible realities. We ensure a seamless transition to commercial production while upholding the highest standards of quality and safety. With our support, you can confidently navigate the complexities of scaling up and bring your innovative solutions to the market.

Pilot Plant

Pilot Plant Services

Custom Chemical Synthesis

InnoSyn provides the ability to scale up chemical processes developed in the lab to pilot-scale production, ensuring the process is efficient, reproducible, and scalable for commercial needs.

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Process Optimization

They optimize chemical processes to ensure economic and environmental efficiency, helping clients to refine their manufacturing workflows before scaling up further.

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Flexible Reactor Systems

InnoSyn provideThe pilot plants at InnoSyn are often equipped with flexible reactor systems capable of handling a wide range of chemistries and production volumes.s the ability to scale up chemical processes developed in the lab to pilot-scale production, ensuring the process is efficient, reproducible, and scalable for commercial needs.

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Safety and Compliance

Pilot plant operations are carried out under strict guidelines, ensuring safety and compliance with international standards.

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Continuous Manufacturing Expertise

InnoSyn is known for its expertise in Flow Chemistry and continuous manufacturing, which are frequently utilized in their pilot plant operations to provide more efficient production solutions.

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Analytical Support

Comprehensive analytical services are integrated into the pilot plant operations to monitor product quality and process performance

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Lab to industrial level

Key Features

The Pilot Plant Service at InnoSyn offers a comprehensive platform to scale up chemical processes from lab to industrial levels. This service focuses on bridging the gap between small-scale laboratory synthesis and full-scale production by providing a controlled, flexible environment to test and refine chemical processes before large-scale commercialization.

This service is crucial for industries like pharmaceuticals, agrochemicals, and fine chemicals, enabling companies to bring new products to market efficiently and safely. This service is crucial for industries like pharmaceuticals, agrochemicals, and fine chemicals, enabling companies to bring new products to market efficiently and safely.

The plant is specifically tailored to optimize, troubleshoot, and validate chemical processes, effectively bridging the gap between lab-scale and full-scale production.

Non-GMP environments provide greater flexibility for process modifications and experimentation, without the stringent documentation or regulatory compliance requirements associated with GMP production.

The primary goal is to ensure that processes developed at a smaller scale (e.g., in a laboratory) can be efficiently and effectively scaled up to larger volumes while maintaining safety, efficiency, and product quality.

Generating the necessary data and understanding for a successful transition to full-scale production facilities.

Developing tailored approaches for specific products to effectively address the unique challenges associated with scale-up.

A non-GMP pilot plant is ideal for companies that aim to accelerate chemical process innovation. By eliminating the complexities of GMP compliance during the early stages of development, the plant supports rapid iteration and learning, which are essential for fine-tuning processes before transitioning to regulated environments, if necessary.

InnoSyn pilot plant offers scalable solutions with flexible systems in process optimization and continuous manufacturing.

Pilot Plant Equipment

  • 140 L stainless steel, 0 to 6 bar, -20 to 200 ˚C
  • 100 L stainless steel, 0 to 40 bar, 0 to 250 ˚C
  • 20 L stainless steel, 0 to 20 bar, -20 to 200 ˚C
  • 300 L Hastelloy, 0 to 60 bar, 0 to 250 ˚C
  • 300 L Hastelloy, 0 to 60 bar, 0 to 250 ˚C
  • 30 L & 135 L glass lined, 0 to 6 bar, -20 to 180 ˚C
  • 200 L glass lined, 0 to 1.5 bar, -20° to 180 ˚C
  • 30 L glass lined, 0 to 1.5 bar, -20° to 110 ˚C
  • Heterogenous catalytic gas phase reactor, up to 400 ˚C
  • Flexible flow reactors, 50 mL to 5 L; up to 5 kg product/hr
  • CryoFlowSkid, up to 5 kg product/hr
  • Multipurpose 10 L - 200 L temperature controlled photoreactor
  • Continuous extraction up to 50 kg/hr for each phase
  • Continuous distillation (~20 theoretical plates), 15 L/hr
  • 0.16 m2 Hastelloy agitated filter dryer
  • 25 L stainless steel ion exchange column
Technology & expertise

Selection of implemented chemistries
& technologies

  • Catalytic hydrogenations
  • Enzymatic transformations (GMO permit)
  • Asymmetric transformations
  • Preferential crystallizations
  • Organometallic chemistry at cryogenic temperatures
  • Continuous processes
  • Hazardous reactions
  • Catalytic oxidations with pure oxygen
  • Falling-film photoreactor, UV & Vis LED-lighting
  • 3D metal printed assets
  • Continuous extraction
  • GMO permits & use
  • Handling hazardous substances (COSHH hazard groups A, B, C, D and E)
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InnoSyn pilot plant offers scalable solutions with flexible systems in process optimization and continuous manufacturing.