Scale-up of chemical processes, particularly those involving batch or semi-batch manufacture is well-known to be a problematic area of chemistry and chemical engineering, and can be costly when it goes wrong. By correctly choosing and designing the synthetic route to a fine chemical or drug substance, as well as controlling the reaction and work up/product isolation parameters, many of the difficulties in scale up can be avoided. The more complex a process is in terms of chemistry and unit operations, the more there is to go wrong. This article discusses what chemists and engineers can do in advance, both in the laboratory and kilo laboratory, to prevent or at least minimise scaleup issues.
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