Pilot success does not guarantee production stability. Scale introduces residence time variation,
thermal gradients, and mixing inefficiencies.
Common Scale-Up Failures:
• Flavour Dilution
• Uneven Distribution
• Process Drift
• Stability Variation
Preventive Actions:
• Simulated Production Trials
• Parameter Documentation
• Cross-Functional Validation
• Batch-to-Batch Sensory Benchmarking
Structured scale-up protocols reduce reformulation cycles and accelerate commercialization
timelines.