• 1-3 FILLELINON STREET, 18536 PIRAEUS GREECE
  • + 30 2100101452
  • contact@prestigeprivatelabel.com

Pilot & Scale-up Support

Pilot production and scale-up are where your lab-tested recipe is trialed in real manufacturing equipment and optimized for mass production. It’s about turning your bench-top beverage into a commercial product without losing quality, functionality, or compliance.

Goals of Pilot & Scale-Up

  • Validate your formulation under real-world production conditions

  • Adjust process parameters (mixing, heating, carbonation, etc.)

  • Identify issues with ingredient behavior, packaging, or machinery

  • Optimize cost per unit (CPU) and production efficiency

  • Provide samples for distribution, testing, or sales

  • Prepare for co-packer onboarding

Key Steps in the Pilot & Scale-Up Process

Pilot Batch Production

This is a small-scale industrial test run using pilot-line machinery. It mimics the real process as closely as possible. Equipment Used: High-shear mixers (for emulsions and powders), Batch kettles (for pasteurization or mixing), Homogenizers, Carbonators (for sparkling beverages),
Filling lines (manual or semi-auto bottling/canning), Pasteurizers / UHT units

Process Engineering & Optimization

Mixing order, Blending times, Pasteurization temperature & duration, Carbonation pressure and CO₂ volume, Filling temperature & headspace control, Design a Standard Operating Procedure (SOP) for production teams

Packaging Line Testing

Confirm container compatibility: Glass, PET, aluminum cans, Tetra Pak, pouches

Shelf-Life and Stability Validation

Conduct real-time and accelerated stability tests post-pilot: Taste drift, pH changes, Sediment or separation, Color or clarity issues, Preservative effectiveness
FEEL FREE TO TALK TO US ABOUT YOUR BEVERAGE PROJECT!
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