There are many factors that should be considered when scaling up chemical processes. However, too often a rigorous assessment of key deliverables from pilots and demo plants is not done, in favour of “base 10” throughput values (1 tonne per day, 10 L/min, 50 kg total). In addition, the review of the reasons why the pilot is being done (beyond showing investors that the scale-up is possible) will give a strong basis for the work and also help to identify design of experiment deficiencies that could reduce the value of the pilot/demo. Some of the factors that will be discussed include sampling and homogeneity, equipment issues, controls, recycle streams, and subsequent materials qualification needs. With a well-planned scale-up, the important factors can be addressed early and de-risking of the project is much more focussed. This chapter will discuss how quantitative analysis of these factors can be used to justify the scale, duration, degree of integration, flow rates, and other features of a pilot/demo plant to ensure that the scale-up maximizes its value