Kilo Lab Systems

Kilo Lab Systems

Our Kilo Lab Systems are advanced glass-based pilot and kilo-scale process platforms engineered to support process development, scale-up validation, and limited batch production under conditions that closely replicate full-scale industrial manufacturing.

Designed using premium Borosilicate Glass 3.3 (SCHOTT DURAN equivalent), these systems provide exceptional chemical resistance, thermal stability, and full process visibility, making them indispensable for pharmaceutical, fine chemical, and specialty chemical industries.

The Kilo Lab System acts as a critical bridge between laboratory R&D and commercial production, enabling safe, repeatable, and data-driven scale-up.

System Architecture & Design Philosophy

Kilo Lab Systems are not standalone reactors — they are fully integrated process assemblies engineered for reaction, distillation, filtration, and separation operations within a single scalable platform.

Core Design Highlights

• All-glass product contact surfaces
• Glass-lined / PTFE-sealed interfaces
• High mechanical stability via SS / coated steel frames
• Modular, expandable configuration
• Transparent construction for real-time monitoring
• EHS-compliant pressure & temperature design

Each system is custom-built based on process chemistry, batch size, operating conditions, and future scalability needs.

How Kilo Lab Systems Work (Process Flow)

• Raw materials are charged into the glass reactor
• Controlled heating or cooling via jacketed heat transfer
• Efficient agitation ensures uniform reaction kinetics
• Vapors routed through columns & condensers (if distillation involved)
• Phase separation / filtration as required
• Product collected in receivers for analysis or next-stage processing

This workflow allows precise replication of plant-level process behavior.

Integrated Sub-Systems Within Kilo Lab Systems

Our Kilo Lab Systems can incorporate the following core sub-products, matching or exceeding competitor offerings:

 Advanced Glass Jacketed Reactor

• Precise thermal control
• Cryogenic to high-temperature operation
• Uniform heat transfer
• Ideal for reaction & synthesis

 Agitated Nutsche Filter (ANF)

• Solid-liquid separation
• Controlled filtration & washing
• Closed-system operation for API & hazardous materials

 Glass Lined Reactor Assembly

• Combines glass corrosion resistance with metal strength
• Suitable for higher mechanical loads
• Ideal for scale-up studies

These systems can operate independently or as an integrated process line.

Key Features & Technical Strengths

•  Borosilicate Glass 3.3 construction
•  Overhead condensers & vapor columns
•  Dean-Stark & reflux arrangements
•  Addition & receiver vessels
•  Phase separators & drain valves
•  Triple-wall reactors (optional)
•  Thermal Control Unit (TCU) compatibility
•  High-precision agitation

Technical Specifications (Representative Range)

Parameter	Specification
Nominal Reactor Capacity	20 L – 200 L
Working Temperature	–50°C to +180°C
Design Temperature	–60°C to +200°C
Working Pressure	Vacuum to +0.8 bar(g)
Jacket Design Pressure	–1 to +0.5 bar(g)
Stirrer Speed	20–192 RPM (Variable)
Heat Transfer Area	0.5 – 2.5 m²
Vapour Line Size	DN 50 – DN 100
Receiver Configuration	Dual receivers for continuous operation
Safety	Rupture disc, vacuum relief, pressure control

Safety, Control & EHS Compliance

•  Pressure-rated glass vessels
•  Accurate temperature monitoring
•  Rupture disc protection
•  Vacuum & inert gas purging
•  CIP-compatible layouts
•  Closed-loop processing

Designed to meet strict Environmental, Health & Safety (EHS) standards.

Why Kilo Lab Systems Are Critical for Scale-Up

•  Reduces commercialization risk
•  Saves development cost
•  Validates reaction feasibility
•  Predicts plant-scale behavior
•  Allows repeated optimization cycles

Kilo Labs enable fail-fast, learn-fast, and scale-safe development.

Industries We Serve

1. Pharmaceuticals (API & intermediates)
2. Fine & specialty chemicals
3. Agrochemicals
4. Biotech & advanced materials
5. R&D institutions & pilot plants

Optional Accessories & Customization

(Standardized accessory pool – mix & match)

•  Heating mantles / oil circulators
•  Chillers & cryogenic systems
•  Reflux dividers & columns
•  Mechanical / magnetic stirrers
•  Vacuum pumps & traps
•  Sensors (PT100, pressure, RPM)
•  Structural frames (MS / SS)
•  PLC / SCADA automation (optional)

Frequently Asked Questions (FAQs)

Q1. Is this suitable for API production?
 Yes, ideal for small-batch API and intermediates.

Q2. Can it simulate full-scale production?
 Yes, designed to replicate plant conditions accurately.

Q3. Can filtration and distillation be integrated?
 Yes, ANF and distillation systems can be fully integrated.

Q4. Is customization available?
 Completely customizable based on process requirements.

Why Choose Our Kilo Lab Systems?

•  Proven industrial designs
•  Trusted by R&D and production teams
•  Modular & future-ready
•  Full visual process control
•  Global export-ready systems