Substantial intensity of ultrasound and high ultrasonic vibration amplitudes are required for many processing applications, such as nano-crystallization, nano-emulsification, deagglomeration, extraction, cell disruption, as well as many others. Commonly, a process is first tested on a laboratory scale to prove feasibility and establish some of the required ultrasonic exposure parameters. After this phase is complete, the process is transferred to a pilot (bench) scale for flow-through pre-production optimization and then to an industrial scale for continuous production. During these scale-up steps, it is essential to make sure that all local exposure conditions (ultrasonic amplitude, cavitation intensity, time spent in the active cavitation zone, etc.) stay the same. If this condition is met, the quality of the final product remains at the optimized level, while the productivity is increased by a predictable "scale-up factor". The productivity increase results from the fact that laboratory, bench and industrial-scale ultrasonic processor systems incorporate progressively larger ultrasonic horns, able to generate progressively larger high-intensity cavitation zones  and, therefore, to process more material per unit of time. This is called "direct scalability". It is important to point out that increasing the power capacity of the ultrasonic processor alone does not result in direct scalability, since it may be (and frequently is) accompanied by a reduction in the ultrasonic amplitude and cavitation intensity. During direct scale-up, all processing conditions must be maintained, while the power rating of the equipment is increased in order to enable the operation of a larger ultrasonic horn.
Finding the optimum operation condition for this equipment is a challenge for process engineers and needs deep knowledge about side effects of ultrasonic processors.