Pilot Plant & Process Scale-Up
From Lab Recipe to Full Production
SantoTolling® takes chemistry that works in the lab and proves it in production-type reactors before you commit to commercial volume. Pilot batches, process adjustments and commercial runs all happen on one 66-acre campus in Spartanburg, South Carolina, so your process is never handed off between sites.
Up to 1.2 Billion Pounds
Annually Produced & Supplied worldwide1
66-Acre Facility
Over a Dozen Specialized Buildings
19 Reactors, 33 Vessels,
67 Tanks & More
Certified Quality
ISO 9001:2015 · ChemStewards · EPA & FIFRA registered · Kosher · Halal
What Is Process Scale-Up?
Prove the Process Before You Commit the Volume
Chemical process scale-up is the work of taking a process proven at lab scale and running it reliably in larger equipment, adjusting for heat transfer, mixing, addition rates and reaction hazards so the product still meets spec at commercial volume. A pilot plant run is the step in between: a batch large enough to behave like production, small enough to fix what doesn't.
Many processes that look simple in a flask behave differently in a reactor. Heat builds faster than it can be removed, mixing slows, and impurities appear that never showed up on the bench. Finding those problems on a pilot batch costs far less than finding them on a full production run.
SantoTolling's chemists and engineers review your process design and scale-up path, run pilot batches in the same reactor types used for commercial production, and provide documentation and test results at every stage. From there, you can move into toll manufacturing, contract manufacturing or take the data with you.
Why Pilot First
What Changes When a Batch Gets Bigger
Scale-up problems are predictable. These are the variables we test and adjust during pilot runs so they don't surprise you in production.
Heat Transfer
Volume grows faster than cooling surface, so a reaction that stayed calm in the lab can run hot in a reactor.
At pilot: we confirm jacket capacity, addition rates and temperature control across -15°C to 300°C.
Mixing & Mass Transfer
Larger vessels change agitation, blend time and how fast phases contact each other, which can shift reaction rates.
At pilot: we match agitation and order of addition to the production reactor you’ll scale into.
Reaction Hazards
Exotherms, gas generation and pressure that were minor at bench scale carry more risk in a full reactor.
At pilot: engineers review hazards before the first run and confirm safe limits up to 500 psig.
Impurities & Yield
Longer heat-up, hold and transfer times can create byproducts that never appeared in the flask.
At pilot: our 24/7 lab tracks in-process samples by GC, LC-MS, NMR and FTIR.
Raw Material Variability
Commercial-grade inputs and new suppliers can behave differently than reagent-grade lab materials.
At pilot: we run the batch with the raw materials planned for production, not lab substitutes.
Downstream Processing
Filtration, distillation, drying and packaging steps often take longer and behave differently at volume.
At pilot: we test the full sequence, including distillation, spray drying and wiped film evaporation.
Who We Work With
Pilot Programs for Every Stage of a Product
New Chemistries
Startups and R&D teams moving from lab or patent to first commercial batches without building a plant.
Established Producers
Manufacturers validating a process change, a new grade or a second source before switching production.
Ag & Crop Protection
Registrants that need pilot material for field trials or data work from an EPA and FIFRA registered site.
Formulators & Brands
Companies that need pilot quantities to sample customers and win qualification before a launch.
Two Programs. One Campus.
Pilot Programs Built Around Your Next Step
Some partners pilot with us and stay for production. Others need pilot material and process data for a decision of their own. Both programs use the same reactors, lab and quality systems.
Option 1
Scale-Up to Production
Pilot Here. Produce Here. No Handoffs.
We take your process from feasibility through pilot batches and straight into commercial runs under a toll or contract manufacturing agreement, all in the same facility.
- Feasibility review of chemistry, equipment fit and safety
- Pilot batches in 300-gallon production-type reactors
- Process adjustments documented batch by batch
- Direct move into reactors up to 12,000 gallons
- No tech transfer between sites and no second learning curve
Best for: companies that want one partner from first pilot batch through ongoing commercial supply.
Option 2
Standalone Pilot Program
Pilot Material. Process Data. Your Decision.
Need product to sample, qualify or field test, or data to decide where to manufacture? We run the pilot and give you the results without a production commitment.
- Pilot quantities for customer sampling and qualification
- Material for field trials and registration work
- Validation of a process change or new grade
- Batch documentation and test results at each stage
- Option to move into production with us later
Best for: product developers, registrants and producers who need proof before choosing a production path.
Already proven at scale? See contract chemical manufacturing.
Why SantoTolling®
What You Gain by Piloting With Us
A pilot run is only as useful as the equipment, data and next step behind it. Here’s what comes with a SantoTolling program.
Pilot to Production on One Campus
Bench, pilot and commercial batches run in one operation, so the people who piloted your process are the ones who produce it.
Data That Carries Over
Pilot batches run in the same glass-lined and stainless steel reactor types used for commercial production, so results translate.
Lower Risk Before You Invest
Find heat, mixing and impurity issues on a pilot batch instead of a full production run or a new plant.
Analytical Data at Every Step
A 24/7 lab with GC, GC-MS, LC-MS, NMR, FTIR and UV-Vis tests raw materials, in-process samples and finished pilot product.
Broad Chemistry Range
Alkoxylation, esterification, polymerization, hydrogenation, quaternization and more, at up to 500 psig and -15°C to 300°C.
Faster Time to Market
Skip building pilot equipment of your own. Your program starts in a permitted, staffed facility under ISO 9001:2015 quality systems.
Stage by Stage
Bench vs. Pilot vs. Commercial Scale
Each stage answers a different question. Here’s how they compare at SantoTolling.
| Stage 1Bench / Lab | Stage 2Pilot Plant | Stage 3Commercial | |
|---|---|---|---|
| Main question | Does the chemistry work? | Does it work in production equipment? | Can it run consistently at volume? |
| Equipment | Lab work supported by our 24/7 analytical lab | 300-gallon glass-lined and stainless steel reactors | Glass-lined to 4,000 gal; stainless steel to 12,000 gal |
| What’s tested | Recipe, raw materials, analytical methods | Heat transfer, mixing, addition rates, hazards, downstream steps | Batch-to-batch consistency and release testing |
| Output | Proof of concept | Pilot product for sampling, trials or qualification | Commercial product, packaged and shipped |
| Documentation | Specs and test methods | Batch records, process parameters, test results | Batch records and certificates under ISO 9001:2015 |
How It Works
From Lab Recipe to Commercial Batch
Every pilot program follows the same five steps, so you know what happens next and who owns it.
Consultation & NDA
We sign a confidentiality agreement, then review your chemistry, current scale and goals.
Feasibility Review
Chemists and engineers assess process design, hazards, equipment fit and raw material sourcing.
Pilot Batches
Runs in 300-gallon reactors with in-process testing by our 24/7 lab.
Optimize & Document
Adjust parameters, confirm spec and record the process for production.
Scale or Hand Off
Move into commercial production on our campus, or take the results with you.
Capabilities Behind Every Pilot
Equipment and Chemistry Range You Can Plan Around
Pilot programs run on the same infrastructure that supports SantoLubes® Manufacturing’s own product lines.
- Glass-lined reactors, 300–4,000 gal; stainless steel, 300–12,000 gal
- Distillation columns (12, 15 and 30 trays) and wiped film evaporator
- Aqueous spray dryers and rotary vacuum dryer
- Dispersion mixers, grinders, homogenizers and venturi mixers
- Alkoxylation, alkylation, amidation, condensation, esterification
- Polymerization, hydrogenation, reductive amination, quaternization
500 psig
Max pressure
-15° to 300°C
Temperature range
10 mm Hg
Vacuum
SantoTolling provides other useful features:
Production-Type Reactors
Pilot in the same reactor types you’ll scale into.
24/7 Analytical Lab
GC, GC-MS, LC-MS, NMR, FTIR, UV-Vis and more.
Storage & Packaging
Pilot product packaged in drums or totes and shipped.
Industries We Serve
Scale-Up for Demanding Markets
Agriculture
Custom synthesis and blending of crop protection formulations and specialty agrochemical intermediates.
Aviation
Contract manufacturing for aerospace-grade fluids and specialty chemical intermediates under strict quality control.
Automotive
Scaled production of specialty fluids, additives, and coatings for OEM and aftermarket supply chains.
Electronics
Precision synthesis and blending for electronics-grade cleaning agents, coatings, and connector treatments.
Lubricants
Full-scale toll manufacturing of synthetic lubricants and base oils, including SantoLubes’ own PPE product line.
Marine
Custom formulation and blending of corrosion-resistant coatings and lubricants for marine and offshore equipment.
Paint & Coatings
Spray drying, blending, and packaging for pigment concentrates, resins, and specialty coating formulations.
Oil & Gas
Contract synthesis and blending of specialty additives and fluids for upstream and midstream operations.
FAQ
Straight answers to what buyers ask us most before a pilot run.
What is a pilot plant in chemical manufacturing?
A pilot plant is an intermediate-scale production setup used to run a chemical process in larger equipment than a lab before committing to full commercial production. At SantoTolling, pilot batches run in 300-gallon glass-lined and stainless steel reactors, the same reactor types used for commercial production on our Spartanburg, South Carolina campus.
What is chemical process scale-up?
Chemical process scale-up is the work of taking a process proven at lab scale and running it reliably in larger equipment. Heat transfer, mixing, addition rates and reaction hazards all change as batch size grows, so the process is adjusted and verified at each step until it produces in-spec product at commercial volume.
Why not go straight from the lab to full production?
Problems that stay hidden at lab scale often show up in larger equipment, including hot spots, slower mixing, longer reaction times and new impurities. A pilot run exposes those issues on a smaller, lower-cost batch, so the commercial process is set before large quantities of raw materials and reactor time are committed.
What batch sizes can SantoTolling pilot and scale to?
SantoTolling pilots in reactors starting at 300 gallons and scales into glass-lined reactors up to 4,000 gallons and stainless steel reactors up to 12,000 gallons. The site has 19 reactors, 33 vessels and 67 tanks, operating at pressures up to 500 psig, temperatures from -15°C to 300°C and vacuum down to 10 mm Hg.
Can I use pilot batches for customer samples or field trials?
Yes. Pilot batches are made under SantoTolling's ISO 9001:2015 quality system and tested in our 24/7 analytical lab, so the material is suitable for customer sampling, qualification runs or field trials when it meets your specifications. For agricultural products, SantoTolling is EPA and FIFRA registered.
Do I have to manufacture with SantoTolling after the pilot?
No. SantoTolling offers pilot and scale-up work as a standalone program or as the first step into toll or contract manufacturing. Documentation and test results are provided at each stage, so you have a record of the process whether production stays on our campus or moves elsewhere.
What happens after a successful pilot run?
Once the pilot confirms the process and the product meets spec, the program can move directly into commercial production on the same campus under a toll or contract manufacturing agreement. Because pilot and production run in the same facility, there is no transfer between sites and no second learning curve.
How do I start a pilot or scale-up project with SantoTolling?
Start with a free consultation by calling (864) 585-3661, emailing sales@santolubes.com or submitting the project form on this page. Share your chemistry, current scale, target commercial volume and any process notes or safety data sheets, and an engineer will follow up to scope the work.
