--- title: "From Lab to Industrial Reality: How to Succeed in Scaling Up | BBA" date: 2025-10-22T00:00:00-04:00 author: Juliette Cote canonical_url: "https://www.bbaconsultants.com/en-ca/publications/between-the-lab-and-industrial-reality-one-factor-makes-all-the-difference-in-scaling-up" section: Publications --- 1. In the world of tech start-ups, there’s no shortage of ideas. The real challenge lies in turning a proof of concept into a reliable, safe and profitable industrial asset. This scale-up phase is as exciting as it is complex: it’s the moment when experimentation gives way to full-scale execution. **”As consultants, our role in scale-up projects is to combine the client’s creativity and expertise with our own to turn a brilliant idea into a feasible project, one that stays on time and on budget,”** explains Olivier Bertrand, Process Engineer at BBA. ### **From idea to industrial reality: a journey marked by key stages** Bridging the gap between the lab and commercial production means moving through a series of stages that validate, refine and de-risk the technology. In innovation terms, this is known as the technology readiness level (TRL). Each level represents another layer of proof of feasibility and reliability, a confidence boost for investors and a step closer to market launch. 1. **Lab (TRL 1–3):** Everything starts here, where engineers explore, test and confirm feasibility. At this stage, they focus on understanding fundamental principles, identifying risks and addressing major uncertainties. This is where the proof of concept emerges, opening the door to initial investment. 2. **Pilot plant (TRL 4–6):** This is the first real-world test. The process is reproduced on an intermediate scale to assess behaviour, yields and stability. It’s a learning environment where testing helps identify unpredictable reactions, fine-tune parameters and strengthen technical confidence. “A pilot plant is designed to make mistakes; it’s a time to learn, fix what doesn’t work and document every lesson to avoid repeating these mistakes,” adds Ulric Chayer, Mechanical Engineer at BBA. 3. **Demonstration plant (TRL 7–8):** This stage confirms the process’s viability under near-industrial conditions. It’s where performance is measured, investors are reassured and the groundwork for production is laid. Though sometimes seen as optional, it’s a critical step. 4. **Commercial plant (TRL 9):** This is the final stage. The technology officially enters the market. By this point, every element must be under control, and the original idea becomes reality. ### **The importance of setting the right pace for scaling up** Many start-ups want to move fast but scaling up can’t be rushed. A process that performs perfectly when tested may behave very differently on a larger scale. A structured, step-by-step approach helps mitigate risks, secure investments and increase success rates because technical, financial and operational challenges evolve as the project grows. ### **Surrounding yourself with the right experts is the best way to move faster** To succeed in scaling up, it’s essential to have a team that can structure the process, plan technical and financial milestones and anticipate regulatory requirements. Start-ups often operate with limited resources and little room for error, which is why partnering with the right experts is so important. You need people who understand your constraints, share your vision and know how to bring it further. Finding the right consultants means finding trusted allies: an experienced team that can advance your technology while managing risk. At BBA, this translates into a hands-on yet agile approach that adapts quickly to the many unexpected twists and turns typical of these projects: - Build a solid execution plan - Set clear priorities - Simplify deliverables - Remain focused on creating value **”Start-ups bring vision and boldness. We bring the credibility needed to make that vision stand strong,”** notes Ulric Chayer, Mechanical Engineer at BBA. ### **When an integrated team becomes the engine of innovation** Scale-up projects require rethinking certain methods, adapting tools and finding new ways to deliver solutions quickly and efficiently. Working within an integrated team, where consultants and clients collaborate side by side, fosters transparency and responsiveness. This proximity builds trust, allows for quick adjustments and enhances the project’s credibility with both investors and regulators. ### **What if success lies in choosing the right team to bring your ideas to life?** This content is for general information purposes only. All rights reserved ©BBA 1. ![Ulric Chayer](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/avatars/_size_avatar/204016/Ulric-Chayer.webp) Ulric Chayer, P.Eng. Department Manager, Mechanical [ ](http://linkedin.com/in/ulric-chayer-540116124) 2. ![Olivier Bertrand](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/avatars/_size_avatar/204018/Olivier-Bertrand.webp) Olivier Bertrand, P.Eng. Process engineer Read bio [ ](http://linkedin.com/in/olivier-bertrand-08266385) **Process engineer with eight years of experience,** Olivier specializes in multi-disciplinary project management, biomass conversion, and process engineering. He supports FEL-1through FEED enfineering phases by translating simulations into concrete design decisions, from PFDs to P&IDs. **Key expertise and certifications** - Natural gas and acid gas processing, material and energy balances - Process design and simulation (Aspen, AFT) - FEED engineering, PFD and P&ID development - Licensed professional engineer (OIQ, APEGA) **Major achievements:** Olivier has delivered projects supporting biomass conversion and process optimization, from FEL-1 through FEED, including simulations, material balances, and other process deliverables. **Approach and added value:** He applies rigorous, practical engineering to strengthen technical decisions, compliance, and operational performance. - [ 27 Jul 2026 Mining and Metals Early tailings decisions shape long-term mine performance - ![Geraldine Cosset](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/avatars/_size_avatar/206707/Geraldine-Cosset.webp) - ![Jared Purdy](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/avatars/_size_avatar/212424/Jared-Purdy.webp) ](https://www.bbaconsultants.com/en-ca/insights/early-tailings-decisions-shape-long-term-mine-performance "Early tailings decisions shape long-term mine performance") - [ 02 Jul 2026 Mining and Metals Python: A key tool for data analysis in mineral processing - ![Charles Blais](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/avatars/_size_avatar/211197/Charles-Blais.webp) - ![Juan Pablo Vergara](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/avatars/_size_avatar/211266/Juan-Pablo-Vergara.webp) ](https://www.bbaconsultants.com/en-ca/insights/python-a-key-tool-for-data-analysis-in-mineral-processing "Python: A key tool for data analysis in mineral processing") - [ 19 Jun 2026 Mining and Metals Speed is earned early in projects - ![Mm employee men jean lheureux retouch web SQ LR BBA](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/avatars/_size_avatar/204266/mm_employee_men_jean-lheureux_retouch_web_SQ_LR_BBA.webp) - ![Mm employee men benoit richard retouch web SQ LR BBA](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/avatars/_size_avatar/203602/mm_employee_men_benoit-richard_retouch_web_SQ_LR_BBA.webp) ](https://www.bbaconsultants.com/en-ca/insights/speed-is-earned-early-in-projects "Speed is earned early in projects") - [ 17 Jun 2026 Industrial data platforms: building a solid foundation to optimize your operations - ![Pierre Boucher](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/avatars/_size_avatar/2671/Pierre-Boucher.webp) Pierre Boucher, P.Eng. Senior Engineer, Operational Technology and Infrastructure ](https://www.bbaconsultants.com/en-ca/insights/industrial-data-platforms-building-a-solid-foundation-to-optimize-your-operations "Industrial data platforms: building a solid foundation to optimize your operations") [ See all ](https://www.bbaconsultants.com/en-ca/insights "Go to Publications listing page") Let’s see what we can do together [ Contact us ](https://www.bbaconsultants.com/en-ca/contact) 1. In the world of tech start-ups, there’s no shortage of ideas. The real challenge lies in turning a proof of concept into a reliable, safe and profitable industrial asset. This scale-up phase is as exciting as it is complex: it’s the moment when experimentation gives way to full-scale execution. **”As consultants, our role in scale-up projects is to combine the client’s creativity and expertise with our own to turn a brilliant idea into a feasible project, one that stays on time and on budget,”** explains Olivier Bertrand, Process Engineer at BBA. ### **From idea to industrial reality: a journey marked by key stages** Bridging the gap between the lab and commercial production means moving through a series of stages that validate, refine and de-risk the technology. In innovation terms, this is known as the technology readiness level (TRL). Each level represents another layer of proof of feasibility and reliability, a confidence boost for investors and a step closer to market launch. 1. **Lab (TRL 1–3):** Everything starts here, where engineers explore, test and confirm feasibility. At this stage, they focus on understanding fundamental principles, identifying risks and addressing major uncertainties. This is where the proof of concept emerges, opening the door to initial investment. 2. **Pilot plant (TRL 4–6):** This is the first real-world test. The process is reproduced on an intermediate scale to assess behaviour, yields and stability. It’s a learning environment where testing helps identify unpredictable reactions, fine-tune parameters and strengthen technical confidence. “A pilot plant is designed to make mistakes; it’s a time to learn, fix what doesn’t work and document every lesson to avoid repeating these mistakes,” adds Ulric Chayer, Mechanical Engineer at BBA. 3. **Demonstration plant (TRL 7–8):** This stage confirms the process’s viability under near-industrial conditions. It’s where performance is measured, investors are reassured and the groundwork for production is laid. Though sometimes seen as optional, it’s a critical step. 4. **Commercial plant (TRL 9):** This is the final stage. The technology officially enters the market. By this point, every element must be under control, and the original idea becomes reality. ### **The importance of setting the right pace for scaling up** Many start-ups want to move fast but scaling up can’t be rushed. A process that performs perfectly when tested may behave very differently on a larger scale. A structured, step-by-step approach helps mitigate risks, secure investments and increase success rates because technical, financial and operational challenges evolve as the project grows. ### **Surrounding yourself with the right experts is the best way to move faster** To succeed in scaling up, it’s essential to have a team that can structure the process, plan technical and financial milestones and anticipate regulatory requirements. Start-ups often operate with limited resources and little room for error, which is why partnering with the right experts is so important. You need people who understand your constraints, share your vision and know how to bring it further. Finding the right consultants means finding trusted allies: an experienced team that can advance your technology while managing risk. At BBA, this translates into a hands-on yet agile approach that adapts quickly to the many unexpected twists and turns typical of these projects: - Build a solid execution plan - Set clear priorities - Simplify deliverables - Remain focused on creating value **”Start-ups bring vision and boldness. We bring the credibility needed to make that vision stand strong,”** notes Ulric Chayer, Mechanical Engineer at BBA. ### **When an integrated team becomes the engine of innovation** Scale-up projects require rethinking certain methods, adapting tools and finding new ways to deliver solutions quickly and efficiently. Working within an integrated team, where consultants and clients collaborate side by side, fosters transparency and responsiveness. This proximity builds trust, allows for quick adjustments and enhances the project’s credibility with both investors and regulators. ### **What if success lies in choosing the right team to bring your ideas to life?** This content is for general information purposes only. All rights reserved ©BBA