Scale up from lab to Commercial

30+ years experience in microwave scale up and design for industrial projects worldwide. Avoid pitfalls and maximise the advantages of microwave technology by benefiting from our experience.

AMT’s Approach to Scaling-Up

AMT use a multistage approach to scaling-up to minimise upfront cost and risk.

A typical project will usually follow a plan similar to bellow:

    1. Project Scope:
      Confirm the scope and aim of the project and determine if it will be theoretically viable.

    2. Literature Review:
      A survey of related articles, reports, papers and patents.

    3. Lab Trials:
      Undertake some preliminary trials with AMT’s existing equipment and applicators, if suitable.

    4. Preliminary Investigation Report:
      Summarise the findings and propose steps and budget for Stage 2.

  • Stage 2 will be undertaken at AMT’s workshop facilities, using existing equipment and any required custom built parts and applicator.

    1. Preliminary Design
      Based on the findings of Stage 1, a preliminary small scale applicator design is drawn up.

    2. Software Simulation
      Starting with the preliminary design, the applicator is modeled, simulated and optimised using 3D Electromagnetic Simulation Software. Main areas of interest will be:
      a. Energy Transfer (Efficiency)
      b. Mode Analysis (Heating Patterns & Even Heating)
      c. Power Density Limitations (Avoiding Voltage Breakdown)

    3. Fabrication
      The optimised applicator is fabricated to be tested at low and high powers.

    4. Low Power (Cold Test)
      Using a Low Power Network Analyser, the applicator is studied for efficiency at room temp and tuned, if required.

    5. High Power Trials & Analysis
      Using AMT’s high power microwave generators, the applicator and process is tested at a range of powers in order to determine if the process is working as intended, what the ideal processing parameters are and confirm it meets regulatory safety standards.

    6. Product Analysis
      The processed material or product may need to be analysed by a third party.

    7. Small Scale Report
      The design process and results are documented in a report and steps and budget for Stage 3 are proposed.

  • Stage 3 consists of developing a medium sized system at AMT’s workshop facilities that should replicate a scaled version of the final commercial system. It may be commisioned off-site at a more suitable location, near completion.

    Stage 3 should provide an opportunity to prove the concept and design is ready for commercialisation, demonstrate the system’s capabilities to potential investors and reveal any unforseen issues before moving to full-scale production.

    1. Preliminary Design
      Based on the findings of Stage 2, a preliminary small scale applicator design is drawn up.

    2. Software Simulation
      Starting with the preliminary design, the applicator is modeled, simulated and optimised using 3D Electromagnetic Simulation Software. Main areas of interest will be:
      a. Energy Transfer (Efficiency)
      b. Mode Analysis (Heating Patterns & Even Heating)
      c. Power Density Limitations (Avoiding Voltage Breakdown)

    3. Applicator Fabrication
      The optimised applicator is fabricated to be tested at low and high powers.

    4. Automation, Mechanical & Electrical Design
      Based on the project’s requirements, all nessesary automation, control systems, materials handeling, safety, mechanical and electrical components are designed and installed.

    5. Low Power (Cold Test)
      Using a Low Power Network Analyser, the applicator is studied for efficiency at room temp and tuned, if required. All control, automation, safety and materials handelling components are tested and checked for correct opperation before microwaves are tested.

    6. High Power Trials & Analysis
      Using AMT’s or a purchased high power microwave generator, the applicator and process is tested at a range of powers in order to determine if the process is working as intended, confirm the ideal processing parameters determined in Stage 2, and confirm it meets regulatory safety standards.

    7. Long term testing
      The process may be tested for an extended period of time.

    8. Product Analysis
      The processed material or product may need to be analysed by a third party.

    9. Pilot Plant Report & Documentation
      The design process and results are documented in a report as well as providing all relevant documentation, schematics and relevant manuals.

  • Based on the success and findings of Stage 3, the project will now be ready for commercialisation.

    At this point, based on the scope of the work, AMT will either undertake this work ourselves or act in a consulting role as the project is undertaken by other party.

  • MICROWAVE APPLICATION SPECIALISTS

    AMT specialize in applying their wealth of microwave related knowledge to a wide range of industrial applications and fields. 30 years experience in microwave scale up and design for industrial projects worldwide. Avoid pitfalls and maximise the advantages of microwave technology by benefiting from our experience.

  • Save Time & Money

    Don’t waste project development time learning from your mistakes. AMT’s extensive knowledge and experience in microwave applications can increase your chance of success and save you time and expenses. We follow a systematic staged approach that minimises your risks and delivers rapid process implementation.

  • CONSULTATION OR COMPLETE SYSTEM?

    Whether it’s consultation, computer simulations, laboratory tests, equipment hire or a complete microwave system, AMT are able to provide the right amount of support for your project. Learn more about AMT’s available services.

  • Expertise & Equipment

    Our expertise is supported by an extensive range of microwave test equipment, 1 kW to 100 kW generators at multiple frequencies, simulation software and workshop facilities to get you started faster.