Scaling Up from Laboratory Drying Tests to Industrial ApplicationsScaling Up from Laboratory Drying Tests to Industrial Applications

In today’s rapidly changing industrial landscape, companies face increasing pressure to innovate, optimize processes, and deliver consistent results. Industrial process development plays a critical role in meeting these demands by ensuring systems are not only efficient but also scalable and reliable. Whether introducing technologies or refining existing ones, the path from laboratory testing to full-scale production is filled with complexities that require careful planning, collaboration, and execution.

“Inspect what you expect.” This quote by a leader and former colleague may be applicable in both a personal and professional sense. It is especially relevant to industrial process development, as expectations are not considered an optional part of any project. Let us imagine for a moment that end users now expect more than the minimum – perhaps previously described as safety, reliability, and cost effectiveness, to name a few. In an industry dominated by discussions of technological advancement, it is vital not to overlook laboratory testing as a key factor in selecting your next drying system.

Small, but production-scale live bottom feeder for use in process development tests (Scott Equipment Co.)

The Challenges of Industrial Process Development

During this phase of process development, there are often challenges to overcome. Those may include: (1) competing priorities for investment resources, (2) variability in wet material available for testing purposes, (3) controlled, usually lab-scale environment and small equipment, and (4) lack of integration with upstream or downstream processes during the development phase. This list is not exhaustive, however, it does highlight opportunities to develop strategies for successfully transitioning from process development testing, or laboratory testing, to full-scale production.

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Strategic planning is crucial when building a business case for selecting a drying system. These activities guide corporate leaders in making informed decisions to remain competitive in today’s market. One can argue that a drying system’s effectiveness directly relates to its continuous performance. This performance is commonly demonstrated in the laboratory testing stage and should be considered a top priority when allocating research and development capital.

Consider two end users with different materials they wish to scale up in a drying system. Both are at a stage where laboratory testing is appropriate before final selection. In one case, a company prepared the worst-case moisture content. This calcium salt material would normally be dewatered to 75 percent solids by means of a filter press prior to being fed into a drying system. However, operators in the plant sometimes encounter a compromised filter which influences the resultant moisture of the filter cake. During such testing, the drying system processed 55-60 percent solids material. While not ideal for scaling and sizing purposes, this scenario is certainly realistic.

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In another case, a corporate team approached sample preparation with extreme care. Excess flocculant was mixed with the wet material before being screw-pressed. While both approaches have advantages, they also pose challenges to the dryer scale-up process. Efforts to reduce variability in feed material may inadvertently fail to represent real-world conditions in a production-scale drying system.

Inside of a dryer/reactor (Scott Equipment Co.)

Bridging Laboratory and Field Performance

Occasionally, the expected performance in the field is lower than what is observed in laboratory conditions. However, with process development testing, it is often reasonable to expect production systems to exceed laboratory-stage expectations.

Laboratory drying tests serve as tools for gathering scale-up data as well as demonstration purposes. To attain favorable results, much of the environment within a laboratory needs to be controlled to an extent. This can make for challenging scale up circumstances, especially when coupled with testing on laboratory scale equipment. While it is not always feasible to test pilot scale equipment, consider an application where an end user is targeting a 15-20X scale up for production purposes. Special attention must be given to ensure scalability in such scenarios.

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Process development initiatives are not limited to just a drying step. Sometimes, material will need to be cooled immediately after it is discharged from the dryer. End users sometime overlook the importance of including additional upstream or downstream processes from their laboratory testing or approach each step as separate development efforts. One should keep in mind the difficulty in replicating the conditions that a downstream process would consist of if that process was a cooling step. While challenging, incorporating these processes during testing helps create a more accurate representation of real-world conditions.

In reviewing these challenges that come with laboratory testing, there are strategies to consider when scaling up drying systems.

Wear from an abrasive application in a test machine (Scott Equipment Co.)

Moving on to Strategies

Businesses continuously prioritize development efforts and decision making amidst economic uncertainty and resource constraints. This makes resources such as time and money extremely valuable. One may consider the following when prioritizing process development decisions:

1. Align process development priorities with long-term business objectives.

2. Leverage industry experts and partnerships with trusted advisors, both internal and external.

When determining which priorities to manage, these strategies can both uncover and foster opportunities that are impactful to one’s business.

Recall the case where an end user prepared the over-flocculated material. The planned laboratory testing was continuous, not batch based. This distinction is important. Batch testing allows for varying sample treatments, while continuous processes make real-time adjustments difficult. To address variability, standardize material collection and consult subject matter experts to determine optimal sample capture points. Additionally, define an acceptable range for test material characteristics.

Laboratory environments are often associated with cleanliness and precision. However, when demonstrating a process on equipment, balance must be maintained between collecting data and showcasing the process itself. Keep these strategies at top of mind when designing the experiment in the laboratory:

1. Conduct thorough research before partnering with a supplier for testing.

2. Choose partners who use small but production-sized equipment for testing.

3. Ensure an adequate quantity of material for testing to maintain steady operation over an extended period.

Well-designed laboratory tests should include upstream or downstream processes where possible. For example, some tests benefit from a back-mix loop, which combines dry material with incoming wet feed. In other cases, cooling the material post-drying is essential. While not always feasible, integrating these processes enhances scalability and system performance.

The strategies discussed provide a roadmap for effective process development, but execution remains the key to success. Translating laboratory findings into full-scale production requires careful coordination, robust communication, and ongoing collaboration between stakeholders. By aligning testing goals with real-world conditions, companies can ensure smoother transitions and successful capital projects.

Make Collaboration Your Best-Known Method

Collaboration is the cornerstone of successful industrial process development. By combining the expertise of suppliers and end users, decision-making and knowledge-sharing improve significantly. When planning your next process development project, accelerate progress by partnering with experts who value collaboration, adaptability, and possess the resources to bring your project to production scale.

By maintaining clear expectations, strategic planning, and a collaborative mindset, businesses can navigate the challenges of industrial process development and achieve long-term success.

Justin Scharpen is business development manager for Scott Equipment’s Thermal Products Group (New Prague, MN). He focuses on driving growth and fostering strategic partnerships within the thermal processing industry. Scott Equipment Co. is a manufacturer of industrial processing equipment, specializing in custom solutions for mixing & blending, bulk storage, feeding, size reduction, and thermal processing across various industries. For more information, call 800-264-9519 or visit scottequipment.comhttps://scottequipment.com/.