Microchannel technology offers the promise of practical process intensification technology for the chemical industry. Capitalizing on the microchannel technology advantage requires demonstrating scalable technology that produces tens to hundreds of tons of product per annum. The transition from lab-scale to industrial-scale chemical processing is described. Specifically, the importance of mass production manufacturing methods, flow distribution, and plant integration are discussed in the context of a case study for a commercial-scale hydrogen generation plant based on microchannel technology. Significant advancements have been made to develop and scale-up microchannel technology, including: Designing complex manifold systems that distribute fluids sufficiently in multi-channel devices, including gas flows exceeding several hundred SLPM over 72 parallel micro-channels that span more than 45 cm in total width and that represent one repeating unit in a full scale device. Fabricating large, high-quality microchannel devices using mass production techniques of stamping, stacking, bonding, and machining to fabricate a scale-up device exceeding 500 kg. Developing a scalable design for numbering-up large scale microchannel devices and integrating within conventional chemical plants.