Scale-up is always a hurdle for crystallisation processes. Conventionally, more attention has been given to achieving consistent size distribution and purity of crystal product in the scale-up from product development stage. However, in recent years, there are new challenges, especially in the pharmaceutical and fine chemical industries, which need to be faced such as polymorph control, cocrystal formation and micro particle or aggregate productions for manufacturing high value crystal products. Such crystal products normally have unique physical or chemical properties which must be maintained at high quality in large scale production. Major factors and criteria for the scale-up of crystallisation from the development stage to manufacturing scale are summarised and discussed in this paper and some novel approaches and attempts are also introduced through case studies.

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