Metal-Organic Frameworks are one of the most exciting materials of recent decades for the chemical industry. After the development of the first MOFs, one of the biggest challenges was to make them accessible for different processes. Their unparalleled surface areas, tunable porosity, and chemical versatility have enabled applications in gas storage, carbon capture, catalysis, and beyond. However, despite their potential, MOFs are not yet accessible on an industrial scale. Here, we aim to take the discussion further and explore what it truly means to make MOFs accessible at an industrial scale—and how we are achieving that vision.
Industrial-Scale MOFs: What Does It Mean?
The first step in producing MOFs is in the lab, on the gram scale. Industrial-scale production means producing MOFs at the kilotonne (kt) or megatonne (MT) level. The scale-up process does not just involve increasing the size of a reactor, but also requires considering critical factors such as:
- Raw material sustainability
- Production efficiency and robustness
- Product quality and performance retention
- Ease of downstream processing
Achieving success in the scale-up process requires combining expertise and a profound understanding of MOF chemistry and engineering.
How We Do It
From years of experience, we conclude that scalability depends on one key factor: recipe stabilization. This means transforming fragile, lab-scale recipes into robust, reproducible processes. The stabilization process addresses every aspect of production including:
- Raw Materials and MOF Compositions: Raw materials are prioritized based on sustainability, ensuring a low environmental footprint from the start. They are also readily available, eliminating bottlenecks in the supply chain. For more on how MOFs contribute to the circular economy and address sustainability challenges, see our blog: Circular Economy - Tackling Challenges with Novel Materials.
- Solvents for Reaction, Work-Up, and Shaping: Traditional MOF recipes rely on toxic and expensive organic solvents like dimethylformamide (DMF). Organic solvents are avoided wherever possible, replacing them with greener alternatives. This shift improves safety, reduces costs, and aligns with global sustainability goals.
- Reaction Conditions: Key factors like pressure, temperature, additives, and reaction times are optimized to ensure:
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- Reproducibility: Consistent results across batches.
- Efficiency: High yields with minimal waste.
- Scalability: The ability to use conventional manufacturing equipment at atmospheric pressure and low temperatures.
- Product Quality: Maintaining—and even improving—MOF performance at scale requires fine-tuning the synthetic procedure. For instance, adjustments in crystal size, porosity, or defect density can significantly impact gas adsorption, catalytic activity, or mechanical stability. For more insights, see our blog about How We Measure and Ensure the High Quality of Our MOFs.
- Product Rheology: Once produced, the MOF powder must be easily processed into its final form—whether as granules, coatings, or nanofibers. Our approach ensures that the as-synthesized material can transition seamlessly into application-specific formats without compromising quality or functionality. Learn more about how particle size affects MOF performance and processing in our blog: Particle Size of Metal-Organic Frameworks.
Example of improved product rheology (left: big agglomerates make downstream processing more challenging; right: novoMOF's methods yield in MOFs in fine powder, comparable to baking flour, that facilitates further processing)
A Recipe for Industrial Success
From our experience, we have found examples of what can be done to improve the scalability of MOF production. In the following table, there are practical examples of real changes applied to MOF synthetic procedures:
Our approach for recipe stabilization has allowed us to produce MOFs on hundreds of kg scale, unlocking MOF production at a tonne scale. By stabilizing and scaling MOF production, we achieve several benefits that resonate with industrial needs:
Positive Life-Cycle Assessment (LCA): MOFs produced via our methods are inherently more sustainable:
- Efficient raw material use minimizes waste.
- Low-energy production reduces carbon emissions.
- High product stability ensures longer lifetimes and less frequent MOF replacement.
- Sustainable end-of-life options (e.g., recyclability, biodegradability) close the loop.
- Cost-Efficiency: Green solvents, low-pressure reactors, and short reaction times translate to lower operational costs, making MOFs economically viable for large-scale deployment.
Are you looking for scalable, sustainable, and economically viable MOF solutions? Whether you need a proven MOF recipe or a custom-designed material tailored to your business case, we’re here to help. Our expertise makes MOFs industrially accessible—paving the way for their widespread adoption in real-world applications.
Contact us today to learn how we can bring your MOF project to life at an industrial scale.
