Pilot Plants, Lab-Scale & R&D Units

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Pilot Plants, Lab-Scale & R&D Units

Introduction

Kerone’s Pilot Plants, Lab-Scale & R&D Units provide the essential bridge between laboratory-scale discovery and full-scale commercial production. These compact, flexible, and precisely instrumented systems allow researchers, process engineers, and product developers to validate process parameters, test new formulations, and optimize production recipes before committing to large-scale capital investment. Kerone designs its pilot and R&D units to be functionally equivalent to their industrial-scale counterparts, ensuring that results obtained at pilot scale are reliably scalable. With modular construction and comprehensive data acquisition systems, these units accelerate product development cycles and reduce scale-up risk across all industries.

Why Choose Kerone Pilot Plants, Lab-Scale & R&D Units

Kerone’s Pilot Plants and R&D Units are built with the same engineering precision and material quality as their full-scale industrial systems, ensuring meaningful and reliable process data that translates directly to commercial scale. Kerone’s units are designed with exceptional flexibility—allowing changes in process configuration, parameter ranges, and measurement points—to accommodate the iterative nature of research and development. Comprehensive data logging, visualization, and analysis tools are integrated into every unit, enabling research teams to extract maximum insight from every trial run. Kerone also offers rental and shared facility options for companies that need pilot testing without a capital purchase.

Types and Features of Pilot Plants, Lab-Scale & R&D Units

Kerone’s R&D and pilot offerings include mini spray dryers, lab fluid bed processors, bench-top microwave and RF dryers, small-scale pyrolysis reactors, pilot heat exchangers, mini evaporators, lab coating chambers, mini extruders, and pilot-scale chemical reactors. All units feature full PLC control, high-resolution data acquisition, easy disassembly for cleaning, and GLP/GMP compatibility. Units are available in tabletop, mobile skid, and small room configurations with capacities from grams per hour to several kilograms per hour.

Key Features

Functionally equivalent design to full-scale systems for reliable scale-up correlation
High-resolution data acquisition and process visualization for detailed experimental analysis
Flexible and reconfigurable process configurations to support diverse experimental programs
GLP/GMP compliant construction for pharmaceutical and food R&D applications
Compact footprint for lab and pilot facility integration without major civil works
Safe operation with comprehensive interlock systems and operator protection measures
Wide range of process parameter control including temperature, pressure, flow, and composition
Easy cleaning and changeover design to support multi-product and multi-formulation testing

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Future-Ready Engineering Driven by AI & IoT

Our advanced AI, ML, and IoT technologies, this solution delivers smarter automation, real-time insights, and predictive intelligence to enhance efficiency and drive future-ready growth.

Real-Time Monitoring & Control

Continuous tracking of process parameters with instant adjustments.

Predictive Maintenance

Intelligent fault detection to prevent failures before they occur.

Adaptive Process Optimization

Dynamic tuning of operations for maximum output and efficiency.

Cloud Dashboards & Analytics

Unified access to real-time insights and performance trends.

Energy & Resource Savings

Smarter utilization of energy to cut costs and reduce waste.

Secure IoT Connectivity

Encrypted data flow with seamless integration across plant systems.

Applications of Pilot Plants, Lab-Scale & R&D Units

Kerone’s Pilot Plants, Lab-Scale & R&D Units are extensively used in pharmaceutical research, food product development, chemical process engineering, and advanced materials research. Typical applications include:

Pharmaceutical API and formulation process development and optimization studies
Food ingredient processing trials for new product development and shelf-life validation
Chemical reaction kinetics studies and catalyst screening using bench-top reactors
Biochar and biomass conversion process optimization at pilot scale
Coating and surface treatment process parameter development for new substrates
Drying and thermal processing development for novel materials with unknown properties

Kerone’s Pilot Plants, Lab-Scale & R&D Units are indispensable tools for organizations committed to innovation, quality, and process excellence. By providing reliable, scalable, and precisely instrumented development platforms, Kerone enables its clients to move from idea to commercial production with confidence, speed, and cost efficiency.

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Frequently Asked Questions (FAQ)

Kerone's pilot units range from lab-scale units processing grams per hour up to pilot-scale systems handling several hundred kilograms per hour, depending on the process type.