We have demonstrated earlier that maximum H-2 generated @ 1.167 l/h/m(2) over Cu0.02Ti0.98O2-delta photocatalyst with apparent quantum efficiency, AQE of 7.5% and solar fuel efficiency, SFE of 3.9% under sunlight. With an aim to scale-up the solar photo catalytic hydrogen process to pilot plant, optimization studies at lab scale as well as in upscaled photoreactors were performed over Cu0.02Ti0.98O2-delta, photocatalyst under UV/visible and sunlight. Cu0.02Ti0.98O2-delta was synthesized by facile sol-gel route and characterized by relevant techniques. Several operational parameters were investigated in order to finalize the conditions which are most favourable for photocatalytic hydrogen yield. Factors such as photocatalyst loadings, v/v concentration of sacrificial reagent, replacement of methanol by industrial waste glycerol, role of different configuration of light source with reactor, effect of stirring during the photocatalytic reaction, effect of fluctuations of solar flux at hourly basis, illumination area on hydrogen yield were studied. Contribution of each factor in determining the hydrogen yield was quantified. Relative standard deviation in hydrogen yield as a function of each factor was estimated. Our findings suggest that in addition to catalyst loadings and sacrificial reagent, improved dispersion of photocatalyst obtained by stirring the reaction mixture in horizontal geometry resulted in enhanced H-2 yield. Hydrogen yield obtained at lab scale can be appropriately extrapolated with respect to illumination area instead of weight of photocatalyst. A relative standard deviation (RSD) of +/- 3.82% and +/- 4.53% in H-2 yield was calculated for sunny and cloudy days in time zone of 10.30-16.30 h IST. Deviation of H-2 yield was more on cloudy days and beyond 16:30 h. These studies have provided a daily window of 11:00-15:00 h to be utilized throughout the year for a commercial scaled up process, prohibiting the illumination during less productive hours of the day for shaping the improved economics of solar hydrogen generation. Our results obtained at lab scale would be useful to perform sunlight driven scaled -up photocatalytic process using low cost visible light efficient photocatalyst, Cu0.02Ti0.98O2-delta (C) 2017 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.