From Lab Bottleneck to Plant Reality: Mastering DIBAL-H Reductions with Flow Technology
On April 14, 2026, InnoSyn hosted the webinar “Breaking Boundaries in Flow Chemistry: Industrial DIBAL-H Reductions Unlocked”, showcasing how a highly challenging reaction can be successfully translated from laboratory concept to industrial reality.
DIBAL-H reductions of esters to aldehydes are well known for their complexity at scale. The reaction proceeds extremely fast, is highly exothermic, and involves unstable intermediates. Traditional batch processing therefore requires deep-cryogenic conditions (−70 to −50 °C) and careful reagent dosing, yet still often results in over-reduction to alcohols, long cycle times, and operational risks.
During the session, InnoSyn demonstrated how continuous flow chemistry, combined with advanced reactor engineering, fundamentally transforms this reaction. By leveraging intensified heat and mass transfer, precise residence-time control, and robust temperature management—supported by technologies such as 3D-printed metal reactors—the process can be safely and efficiently scaled.
The presented DIBAL-H flow process enables:
• Safe handling of highly exothermic chemistry
• Stable operation without extreme cryogenic conditions
• Reduced formation of over-reduction side-products
• Scalable and controlled aldehyde production at industrial throughput
This breakthrough highlights how flow chemistry can unlock transformations previously considered too hazardous or impractical for manufacturing—pushing the boundaries of modern process development.
The webinar was led by Raf Reintjens, Principal Scientist in Flow Chemistry at InnoSyn, who shared insights from his extensive experience in process development, scale-up, and process intensification. His work focuses on translating complex chemistries into robust and scalable flow solutions, particularly for highly exothermic and cryogenic reactions.
👉 Watch the full webinar recording:
https://innosyn.com/webinar/video/webinar-1