The scale-up of high precision nanoparticles is challenged by the high cost of structure directing agents, high energy operating conditions and low space time yields. Annular flow microreactor technology presents a more efficient alternative to conventional batch and microfluidic techniques, by utilizing high and uniform hydrodynamic shear rates to produce particles with highly tailored structures. Accelerated Materials has recently built commercial annular microreactor systems for synthesis of particles at the approx. 1 kg/day, 10 kg/day and 100 kg/day scales. In this talk, we describe the development of the systems across scales, as well as our validation of system quality using nanoparticle zinc oxide as a case study. We optimized nano ZnO (ZnO NP) to achieve superior antimicrobial properties, making it ideal for use in coatings, medical applications, and advanced materials. Unlike conventional ZnO, which is typically spherical, our research found that a flake-like structure provides stronger antimicrobial effects by disrupting bacterial membranes more effectively. To ensure consistent quality, we closely monitored reaction conditions, purity, and product performance at all production stages. Advanced testing confirmed that ZnO NPs produced at different scales remained highly effective, stable, and safe. Beyond scientific improvements, this work also brings major economic benefits. Our technoeconomic analysis showed that we may reduce costs by 86% and shortened the time required for large-scale manufacturing from 5 years to just 6 months. This breakthrough makes it possible to produce high-performance ZnO NPs more efficiently and affordably, supporting their use in industries requiring antimicrobial and UV-protective solutions
