We report mixing characterization of five lab-scale and eight production-scale static mixers using a modified fourth Bourne reaction. An efficient inline method relying on UV–vis spectroscopy was developed to streamline analysis of the product distribution. As a result of these studies, we have designed, 3D-printed, and characterized a stainless steel static mixer. This approach enabled the evaluation of different configurations and ensured efficient scale-up across development and commercial facilities that should allow for enhanced portability of mixing-sensitive processes.

• Merck & Co., Inc.

• Intermediate

1. Bourne reaction
2. in-line analysis
3. Intermediate
4. Research Article
5. Scale-up
6. static mixer
7. UV/Vis spectroscopy