Pilot Plant Essentials
Posted by HTT Magazine on 17th Feb 2026
Lab Scale vs Process Scale Rotary Evaporators
Why rotovap scale matters in chemical engineering
Rotary evaporators are common in both research labs and pilot plants—but the requirements are radically different.
A system designed for:
- graduate lab work
will struggle in: - kilo lab solvent recovery
- pilot plant distillation
- process development environments
Understanding the difference between lab-scale and process-scale rotovaps prevents costly under-sizing.
Lab-scale rotary evaporators (typical features)
Designed for:
- small batch solvent removal
- academic research workflows
- limited daily runtime
Typical traits:
- 1–5L flask sizes
- moderate duty cycles
- compact footprint
- basic vacuum integration
These units excel in flexibility but struggle in sustained throughput environments.
Process-scale rotary evaporators
Designed for:
- continuous or high-volume solvent recovery
- pilot plants and process chemistry
- long duty cycles
Typical features:
- 10L–50L+ flasks
- heavy-duty drives
- robust seals
- industrial chillers and vacuum systems
Process units prioritize durability and throughput, not compactness.
The 5 biggest differences that impact scale-up
1) Throughput capacity
Process rotovaps can recover solvent much faster due to:
- larger surface area
- higher vapor handling capacity
- stronger vacuum systems
2) Mechanical durability
Pilot plant equipment must handle:
- longer run times
- higher loads
- harsher solvents
Lab units may fail prematurely under continuous duty.
3) Cooling infrastructure
Process-scale systems require:
- industrial chillers
- higher coolant flow
- better condenser design
This is where many scale-ups fail.
4) Vacuum system integration
Process rotovaps often require:
- deeper vacuum capability
- higher flow pumps
- vapor protection systems
Basic diaphragm pumps rarely suffice at larger scales. Explore our inventory.
5) Safety considerations
Larger solvent volumes introduce:
- flammability risks
- mechanical hazards
- vapor management challenges
Process-scale equipment often incorporates additional safety engineering.
When labs should upgrade
Consider moving to process-scale rotovaps if:
- solvent recovery becomes a bottleneck
- batches exceed 5–10L regularly
- multiple daily runs are required
- energy efficiency becomes important
Buying used process rotovaps
Inspect:
- drive torque and stability
- seal condition
- condenser surface area
- vacuum compatibility
- structural integrity of frames
Industrial rotovaps can deliver strong ROI when purchased refurbished.
FAQ
Can I run a lab rotovap harder instead of upgrading?
Sometimes temporarily—but long-term reliability suffers.
Are process rotovaps only for manufacturing?
No. Many pilot plants use them during process development and solvent screening.
CTA:
If your lab is transitioning from bench to pilot scale, tell HiTechTrader your solvent volumes and recovery goals. We can help you identify rotary evaporators designed for real process throughput.