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How to Scale-Up Organic Sample Preparation

May 19, 2025

Scaling up organic sample preparation — from lab-scale methods to larger batch or continuous processing — presents both technical and operational challenges. In industries such as environmental testing, food and beverage, or pharmaceuticals, maintaining data integrity while increasing throughput is crucial. Effective scale-up is not simply a matter of using larger equipment; it requires thoughtful adjustments to extraction methods, mixing, digestion, evaporation, and automation. ATS-Scientific offers a full spectrum of scalable sample preparation solutions, helping laboratories meet the demand for volume without compromising quality or compliance.

Why Scale-Up Matters

As labs move from R&D or quality control environments to pilot-scale production or routine high-throughput testing, scaling up sample prep becomes essential. However, larger batch sizes can introduce new variables—such as uneven heating, poor homogenization, solvent loss, or lower extraction efficiency. By anticipating and addressing these issues, labs can reduce method variability, improve reproducibility, and stay aligned with regulatory standards.

Key Considerations When Scaling

  • Nonlinear Process Effects: Doubling the sample size doesn’t always mean doubling the output. Variables like solvent penetration, temperature distribution, and reaction kinetics behave differently at scale. Homogeneity and reproducibility can suffer if scale-up isn’t engineered carefully.

  • Equipment Geometry and Design: Larger vessels or extraction chambers have different surface-area-to-volume ratios, which can affect heat transfer and mixing. ATS-Scientific’s sample prep instruments, including high-capacity homogenizers and solvent extractors, are designed to maintain efficiency and consistency across a range of scales.

  • Safety and Environmental Control: Handling greater volumes of solvents or potentially hazardous samples increases the importance of closed systems, pressure control, and solvent recovery. ATS offers automated digestion and distillation systems with integrated safety features and exhaust management.

Scalable Sample Preparation Solutions from ATS

  • Bulk Homogenization and Grinding: Consistent particle size is key to representative sampling and efficient extraction. ATS provides cryogenic and high-capacity mills for homogenizing tough or temperature-sensitive samples at scale.

  • High-Throughput Solvent Extraction: Accelerated Solvent Extraction (ASE) and automated Soxhlet systems enable fast, repeatable extraction of analytes from complex matrices. ATS’s extractor units are designed for batch processing with programmable parameters, making them ideal for scaling standard AOAC or EPA methods.

  • Automated Digestion and Distillation: For analyses requiring protein, nitrogen, or fiber quantification, ATS offers digestion units with multiple-sample handling capabilities, such as 6- or 20-place digesters, along with matching distillation systems. These systems ensure uniform heating and reduce manual error, key for accurate Kjeldahl or sulfur analysis.

  • Evaporation and Concentration: Large-capacity rotary evaporators and vacuum concentrators are essential when scaling up extraction workflows. ATS provides solvent recovery solutions that maintain safety and minimize energy use while preserving analyte integrity.

Automation and Workflow Integration

Automation plays a critical role in ensuring consistency and reducing hands-on time as sample volumes increase. ATS instruments support autosamplers, programmable protocols, barcode tracking, and LIMS integration to streamline scaled-up workflows. Many systems feature built-in temperature, pressure, and solvent flow monitoring to ensure that scaled protocols stay within validated ranges.

Furthermore, ATS’s instrumentation complies with key standards (AOAC, EPA, ISO), which supports method transferability from lab to production environments.

Maintaining Analytical Quality at Scale

  • Method Validation: Scaled-up methods should be validated against their lab-scale counterparts using certified reference materials and recovery testing. Consistency in extraction efficiency, analyte recovery, and reproducibility must be demonstrated to maintain analytical integrity.

  • Quality Assurance and Regulatory Compliance: Implementing QC checkpoints throughout the sample prep process—such as blanks, spikes, and duplicates—helps identify deviations early. ATS provides guidance on instrument maintenance and calibration routines to ensure long-term reliability.

  • Documentation and Traceability: With increasing sample loads, digital documentation becomes even more important. ATS’s data systems support audit-ready recordkeeping, method traceability, and automated reporting to support regulatory audits and client transparency.

Looking to Scale Your Organic Sample Preparation?

Scaling up organic sample preparation is a complex but manageable process when approached methodically. From adjusting solvent ratios and heating profiles to adopting higher-capacity equipment and automation, each decision influences analytical quality and efficiency.

ATS-Scientific’s scalable solutions—including homogenizers, solvent extractors, digestion/distillation systems, and evaporators—are engineered for performance, safety, and regulatory alignment. Whether you’re scaling up for routine analysis or preparing for commercial production, ATS’s expertise and technology can help you bridge the gap between precision and productivity.