How to prepare for a scale-up run: a practical checklist

Scale-up runs are where good products succeed or fail. Preparation is the difference between learning fast and burning time. This checklist keeps the run focused and the data usable.

Before the run

• Confirm the final bench formula and target specs.
• Lock ingredient suppliers and verify lead times.
• Align on the process steps and critical control points.
• Define success criteria for texture, taste, and yield.

Data and materials to bring

• Updated formulation and ingredient specs
• Target process parameters (time, temperature, shear)
• Packaging requirements and fill targets
• Sampling plan and sensory evaluation criteria

During the run

• Record deviations and changes immediately.
• Capture yield, moisture, and in-process metrics.
• Collect samples for stability and sensory review.

After the run

• Summarize outcomes versus target specs.
• Update the process document with real parameters.
• Decide whether to repeat, adjust, or move to validation.

Common scale-up risks

• Ingredient substitutions at the last minute
• Unclear decision criteria for passing the run
• Missing data that prevents a clean handoff

If you want support on your first pilot, we can run a pre-pilot readiness review and identify any gaps before you commit to a run.