Laboratory and Pilot Plants

What is a Research & Pilot Plant?

A pilot plant helps bridge the gap between laboratory experiments and full-scale production. They enable the optimization of chemical processes under realistic flow condition, before a large-scale demonstration plant or a manufacturing plant. They support scale-up decisions and process robustness and can also be used for small production capacities.

With 30 years of experience, more than 250 laboratory and pilot plants delivered worldwide and over 100 satisfied customers, we realize even complex systems for demanding processes quickly and cost-effectively.

Our systems are always calculated and manufactured to order. You can view the typical course of a project and typical delivery times here. If you require a specific quotation, please send us an inquiry. Please note that the more information you give us about your process, the more detailed our quotation will be.

Why Choose AP-Miniplant for Your Project?

At AP-Miniplant, we design and build custom pilot plants and research systems optimized for your specific process requirements.

Flexibility

We design our plants according to your individual requirements. You get tailor-made solutions to ensure that each installation fits your requirements perfectly.

User-Friendliness

We focus on easily accessible controls, clear design and intuitive user interfaces during planning, construction and automation.

Affordable Solutions

Thanks to our many years of experience and a broad network of suppliers, we can offer you cost-effective options with high quality and reliability.

Automation

Anyone who operates a plant knows that well thought-out and reliable automation makes all the difference! That’s why we at AP-Miniplant use PLCs as standard in our automation, which are programmed and tested according to customer specifications.

Extensive Support

We are also at your disposal after delivery. Our service team will be happy to help you with any questions, problems or change requests.

Our scope of services

We offer our laboratory and pilot plants for a wide range of various industries, e.g. chemical or polymer industry. as a complete package, including

Consulting and concept development

Detailed planning

Procurement of all system components

Construction of the plant (incl. electrical connection and insulation if necessary)

Automation

Testing (incl. leak test, pressure test, function test, etc.)

Shipping

Commissioning

Documentation (incl. CE and TÜV certification)

We can also offer you optional services if required:

Explosion protection according to ATEX directive

GMP-ready with FDA-certified materials

Typical Pilot Plant Applications

We offer a wide range of different types of systems. Here you will find a selection of process tasks and test systems that we can realize individually or interconnected. Whether you need a small production plant, a pilot plant or a complete test system for your research and development – AP Miniplant supports you in realizing your process.

Unit Operations

Absorption
Adsorption
Humidification
Distillation
Extraction
Precipitation
Filtration
Mixing
Distillation
Rectification
Reactive rectification
Drying
Evaporation

Reactors and Vessels

Fixed bed reactors
Continuous reactors
Storage vessels
Metal-free vessels
Membrane reactors
Polymerization reactors
Reactive distillation
Stirred reactors
Tube furnaces
Fluidized bed reactors
Special reactors

Functional Units

Fuel cell test rigs
Electrolysis test rigs
Catalyst test systems
Dosing systems
Electrosynthesis
Gas treatment
Recycling plants

Ready to Start your Pilot Plant Project?

Submit your process requirements for a personalized quote, including technical feasibility and budget estimate.

Get your quote

How far can a pilot plant be customized to my process?

Pilot plants can be customized to a very high degree, as they are typically engineered around a specific process rather than based on fixed standard designs. This includes reactor configuration, materials of construction, peripheral equipment, safety concepts and automation depth. Where appropriate, proven modules can be combined with fully custom-engineered components to balance flexibility, cost and lead time.

Which operating ranges can be realistically covered?

Pilot plants are designed and manufactured in compliance with the Pressure Equipment Directive 2014/68/EU (PED). AP-Miniplant operates a certified quality management system in accordance with Module H, certified by TÜV Thüringen.
Through appropriate selection of materials and equipment design, operating temperatures of up to 1,000 °C and pressures of more than 100 bar can be realised where required. Depending on the application, throughput can range from a few millilitres per hour up to several hundred kilograms per hour. All operating limits are defined during the engineering phase to ensure safe, controllable and representative pilot-scale operation.

How is automation and data acquisition implemented?

Automation is implemented using PLC-based control systems built on the latest Siemens automation architecture. All implemented control strategies, interlocks and safety functions are thoroughly tested prior to delivery.
High-quality automation is a key focus at AP-Miniplant, as reliable process control and reproducible data are essential for meaningful pilot plant operation. A well-designed automation concept is often what distinguishes a robust pilot plant from an unusable one. Process data can be continuously recorded and made available for analysis, reporting and scale-up evaluation.

Can pilot plants be realised as modular or containerized systems?

Yes, pilot plants can be realised as modular or fully containerized systems without compromising process performance, safety or automation quality. For modular systems, automation concepts can also be implemented in accordance with the Module Type Package (MTP) standard, allowing flexible integration and reuse of individual process modules.
Such solutions are particularly advantageous where space is limited, installation time needs to be minimized or pilot plants need to be relocated between different sites.

What experience do you have with complex or non-standard processes?

AP-Miniplant has extensive experience with complex and non-standard processes, including highly viscous material systems, demanding dosing tasks and individually configured apparatuses. Wherever possible, proven and cost-efficient standard components are used. At the same time, numerous custom solutions can be developed in-house or realised through a well-established network of specialized suppliers. This approach allows even highly challenging process requirements to be implemented reliably.