In the world of chemical, pharmaceutical, and process manufacturing, the path from concept to commercial-scale production is paved with both opportunity and risk. Making the wrong decision early can lead to costly setbacks, process inefficiencies, or even full system redesigns. That’s why more and more companies are recognizing the power of small-scale testing as a critical foundation for process success.
At De Dietrich, our Swedesboro, New Jersey test center is equipped to help customers take advantage of this strategic step. Through feasibility testing, lab and pilot-scale simulations, and comparative technology trials, we help clients minimize risk, accelerate development, and set the stage for efficient and reliable production.
The Role of Small-Scale Testing in Process Development
Before committing to full-scale production equipment, it’s essential to understand how a process behaves under controlled conditions. Small-scale testing—whether at the benchtop or pilot scale—allows engineers and project teams to examine process parameters, troubleshoot challenges, and optimize equipment configurations.
Key advantages of small-scale testing include:
- Risk Reduction: Detect potential performance issues before major investments are made.
- Cost Efficiency: Use minimal raw materials and resources to simulate full-scale performance.
- Process Optimization: Fine-tune parameters such as temperature, pressure, mixing, and filtration.
- Scalability Insights: Evaluate how core process dynamics may shift as you move up in volume.
These early insights help validate not only the technical viability of a process but also its economic and operational feasibility.
From Concept to Production: The Testing Continuum
Small-scale testing is not a one-time event; it is a continuum that supports every phase of development:
- Feasibility Testing: Initial benchtop experiments confirm whether a selected process or technology can handle your specific material or chemistry.
- Lab-Scale Process Optimization: Larger batches are used to refine parameters, identify critical process variables, and create reproducible conditions.
- Pilot-Scale Verification: At this scale, tests simulate production-like conditions, verifying that results can be repeated with larger volumes and under more complex scenarios.
- Technology Transfer: Testing results directly support the development of scale-up strategies and production equipment specifications.
- Post-Transfer Support: Ongoing testing helps troubleshoot issues and support process improvements even after commercial production has begun.
Each of these steps is supported at our Swedesboro test center with the right tools, technologies, and technical expertise to help you move confidently toward production.
Real-World Example: Avoiding Surprises in Solid-Liquid Separation
In a recent project, a customer in the specialty chemicals sector engaged our team to evaluate two different solid-liquid separation methods: a nutsche filter-dryer and an inverting filter centrifuge. Using side-by-side testing with the same slurry material, we were able to evaluate key metrics like solids capture, drying time, and wash efficiency.
The results? The inverting centrifuge demonstrated faster cycle times and better moisture removal, providing clear data to support equipment selection. Without these trials, the customer might have invested in a less efficient solution that would have underperformed at scale.
Long-Term Payoff: ROI from Early Testing
While testing requires time and resources upfront, it delivers a significant return on investment:
- Reduces scale-up failures
- Shortens time-to-market
- Improves product quality and consistency
- Supports regulatory compliance and documentation
- Enables better capital planning and equipment sizing
In highly regulated and cost-sensitive industries, these benefits are not just helpful—they are essential.
Experience It for Yourself at Our Swedesboro Test Center
De Dietrich’s Swedesboro, NJ Test Center is designed to be a partner in your process development journey. With a wide range of testing equipment, experienced engineers, and a focus on real-world results, we help clients develop, validate, and scale up their processes with confidence. Contact us today to schedule a consultation to see what small-scale testing can do for your process.
Want to dive deeper into the value of small-scale testing? Our white paper, “Testing for Success: Lab/Pilot Testing for Chemical Applications,” provides an in-depth look at how structured testing can reduce risk, improve process performance, and ensure a smoother path from development to production. Download the White Paper and discover how smart testing leads to better outcomes.
