Common scale-up methods are conventional where the blind piloting is essential. This imposes huge investment and leads to failures mostly in solid processing. However, the limitations of resources, current shortcomings, short time-to-market demand are forcing companies to minimize piloting. With these situations in mind, current digitalization outlook and computational facilities, we proposed and developed a novel iterative scale up method with case studies which highly expedites the process innovation through the following key sequences:

• To move from literature and laboratory studies to commercial design.
• To reduce risks by reevaluating literature, lab studies, e-pilot or adequate pilots if needed.
• To iterate between commercial to lab, e-pilot and pilot with CAPEX, OPEX and LCA.