--- title: The technical risks of process commercialization date: 2025-05-15T10:44:00-04:00 author: Florence Côté canonical_url: "https://www.bbaconsultants.com/en-ca/publications/the-technical-risks-of-process-commercialization" section: Publications --- We often hear about groundbreaking solutions designed to combat global warming, produce green energy or improve living conditions. These innovations include alloy powders for 3D printing, anode and cathode powders for high-capacity batteries and additives such as graphene that enhance the properties of everyday objects. They also include catalysts used in green hydrogen production. Producing these new materials often involves developing innovative manufacturing processes. Successfully commercialized innovations typically come from manufacturing processes that have migrated from the lab to full industrial scale while navigating two major risk categories: technical and commercial. This article explores technical risks, while a future article will address commercial risks. 1. ## One process, three stages Developing an innovative manufacturing process generally involves three key stages: lab research, pilot testing and an industrial-scale production. Figure 1 illustrates how project cost estimates evolve with project maturity within an industrial setting. At the lab stage, the new manufacturing process is still taking shape and requires minimal investment. However, the pilot stage is where the full production chain is tested and confirmed. This stage involves significantly higher investment, since larger and more complex equipment is required. Nevertheless, it helps refine the process for industrial-scale production and reduces risks involved in the final stage. 2. Figure 1 – The three stages of commercialization [ ![The technical risks of process commercialization](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/The-technical-risks-of-process-commercialization.png) ](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/The-technical-risks-of-process-commercialization.png) 3. ## Lab production The technical risks associated with this initial development stage include: - Technological uncertainties in manufacturing steps - Variability in raw material sources and other inputs - Health, safety and environmental (HSE) challenges - Unclear pathways for scaling up to industrial production Despite limited resources, the lab manufacturing stage helps identify the technologies, equipment, services and raw materials needed to create the final product while mitigating risks associated with technological choices. During this prototyping phase, manufacturing methods are documented, and by-products are identified and integrated into the business model. A preliminary list of equipment, products and by-products required for the process helps identify HSE risks and determine mitigation measures—these risks are numerous and have already been addressed [in a previous article](https://www.bba.ca/publications/metal-powder-production-ohs-risks-first). By the end of the lab phase, a vision for the industrial plant takes shape, allowing the critical path to be defined. However, developing a new process or product is complex and challenging. Unexpected issues or phenomena will arise during lab work, often slowing progress. To help clients navigate these challenges, BBA provides access to experts with extensive industry networks who can quickly identify solutions. 4. ## The pilot stage This stage defines and validates a complete process that meets market expectations while preparing for industrial-scale production. Key risks to address at this stage include: - Inefficient production - Variable quality - HSE challenges - Lack of a [startup and operational](https://www.bba.ca/publications/operational-readiness-and-commissioning-plans-the-key-to-a-successful-start) strategy The pilot stage helps reduce risks associated with scaling up production by refining equipment and material choices and selecting efficient material transfer methods between processing stages, from intake to final output. It also improves operational efficiency by developing a preliminary operating philosophy with relevant performance indicators and execution strategies for future key production functions. By the end of this stage, products and [quality](https://www.bba.ca/publications/metal-powder-production-quality-control-is-crucial) are sufficiently stable, HSE risks have been identified and resolved and a ramp-up strategy is in place to achieve business plan objectives. Pilot facilities can differ greatly, depending on a number of factors. In some cases, a small-scale pilot plant in a leased industrial space will suffice, while in others, a full-scale pilot plant in an industrial zone may be necessary. Choosing the right pilot strategy must therefore account for commercial challenges that need to be addressed to achieve the intended objectives. To support this process, BBA offers expertise in process commercialization and operational readiness, helping define production scale-up strategies and other needs at this stage. 5. ## Industrial plants Key risks to address at this stage include: - Cost overruns or project delays - Startup issues - Low productivity - HSE challenges Industrial-scale production begins with a detailed engineering study to build a high-capacity facility, incorporating lessons learned from the lab and pilot stages. This is the most expensive phase of commercialization, and reducing risks in earlier stages helps strengthen project credibility, reassuring public and private investors. BBA provides engineering, procurement, construction management and commissioning services for industrial plant projects. With experience in commercialization, construction and process startup, BBA’s multidisciplinary team can deliver highly complex and innovative projects successfully. 6. ## Conclusion Commercializing a process involves both known and unknown risks that must be mitigated. By structuring project development into three stages—lab, pilot and industrial-scale production—you can prioritize risks and optimize investments. Scaling up from the lab to full industrial production is highly complex. Expert input from engineers and specialists is needed to develop a plan that optimizes quality, costs, efficiency and HSE. For any project involving the commercialization of innovative processes, feel free to contact BBA. This content is for general information purposes only. All rights reserved ©BBA 1. ![Benoit Desjardins](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/avatars/_size_avatar/92110/Benoit-Desjardins.webp) Benoit Desjardins, P.Eng. Senior Engineer, Operational Readiness and Commissioning [ ](https://www.linkedin.com/in/beno%C3%AEt-desjardins-ing-8a9b2484/) - [ 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 think it further together [ Contact us ](https://www.bbaconsultants.com/en-ca/contact) We often hear about groundbreaking solutions designed to combat global warming, produce green energy or improve living conditions. These innovations include alloy powders for 3D printing, anode and cathode powders for high-capacity batteries and additives such as graphene that enhance the properties of everyday objects. They also include catalysts used in green hydrogen production. Producing these new materials often involves developing innovative manufacturing processes. Successfully commercialized innovations typically come from manufacturing processes that have migrated from the lab to full industrial scale while navigating two major risk categories: technical and commercial. This article explores technical risks, while a future article will address commercial risks. 1. ## One process, three stages Developing an innovative manufacturing process generally involves three key stages: lab research, pilot testing and an industrial-scale production. Figure 1 illustrates how project cost estimates evolve with project maturity within an industrial setting. At the lab stage, the new manufacturing process is still taking shape and requires minimal investment. However, the pilot stage is where the full production chain is tested and confirmed. This stage involves significantly higher investment, since larger and more complex equipment is required. Nevertheless, it helps refine the process for industrial-scale production and reduces risks involved in the final stage. 2. Figure 1 – The three stages of commercialization [ ![The technical risks of process commercialization](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/The-technical-risks-of-process-commercialization.png) ](https://www.assets.bbaconsultants.com/bba-production-assets/production/images/The-technical-risks-of-process-commercialization.png) 3. ## Lab production The technical risks associated with this initial development stage include: - Technological uncertainties in manufacturing steps - Variability in raw material sources and other inputs - Health, safety and environmental (HSE) challenges - Unclear pathways for scaling up to industrial production Despite limited resources, the lab manufacturing stage helps identify the technologies, equipment, services and raw materials needed to create the final product while mitigating risks associated with technological choices. During this prototyping phase, manufacturing methods are documented, and by-products are identified and integrated into the business model. A preliminary list of equipment, products and by-products required for the process helps identify HSE risks and determine mitigation measures—these risks are numerous and have already been addressed [in a previous article](https://www.bba.ca/publications/metal-powder-production-ohs-risks-first). By the end of the lab phase, a vision for the industrial plant takes shape, allowing the critical path to be defined. However, developing a new process or product is complex and challenging. Unexpected issues or phenomena will arise during lab work, often slowing progress. To help clients navigate these challenges, BBA provides access to experts with extensive industry networks who can quickly identify solutions. 4. ## The pilot stage This stage defines and validates a complete process that meets market expectations while preparing for industrial-scale production. Key risks to address at this stage include: - Inefficient production - Variable quality - HSE challenges - Lack of a [startup and operational](https://www.bba.ca/publications/operational-readiness-and-commissioning-plans-the-key-to-a-successful-start) strategy The pilot stage helps reduce risks associated with scaling up production by refining equipment and material choices and selecting efficient material transfer methods between processing stages, from intake to final output. It also improves operational efficiency by developing a preliminary operating philosophy with relevant performance indicators and execution strategies for future key production functions. By the end of this stage, products and [quality](https://www.bba.ca/publications/metal-powder-production-quality-control-is-crucial) are sufficiently stable, HSE risks have been identified and resolved and a ramp-up strategy is in place to achieve business plan objectives. Pilot facilities can differ greatly, depending on a number of factors. In some cases, a small-scale pilot plant in a leased industrial space will suffice, while in others, a full-scale pilot plant in an industrial zone may be necessary. Choosing the right pilot strategy must therefore account for commercial challenges that need to be addressed to achieve the intended objectives. To support this process, BBA offers expertise in process commercialization and operational readiness, helping define production scale-up strategies and other needs at this stage. 5. ## Industrial plants Key risks to address at this stage include: - Cost overruns or project delays - Startup issues - Low productivity - HSE challenges Industrial-scale production begins with a detailed engineering study to build a high-capacity facility, incorporating lessons learned from the lab and pilot stages. This is the most expensive phase of commercialization, and reducing risks in earlier stages helps strengthen project credibility, reassuring public and private investors. BBA provides engineering, procurement, construction management and commissioning services for industrial plant projects. With experience in commercialization, construction and process startup, BBA’s multidisciplinary team can deliver highly complex and innovative projects successfully. 6. ## Conclusion Commercializing a process involves both known and unknown risks that must be mitigated. By structuring project development into three stages—lab, pilot and industrial-scale production—you can prioritize risks and optimize investments. Scaling up from the lab to full industrial production is highly complex. Expert input from engineers and specialists is needed to develop a plan that optimizes quality, costs, efficiency and HSE. For any project involving the commercialization of innovative processes, feel free to contact BBA. This content is for general information purposes only. All rights reserved ©BBA