In this paper, start-up of a plate reactor is considered. Dynamic optimization is used to obtain start-up trajectories, and a feedback control structure for on-line control. The problem is challenging, since the process model is large and highly non-linear. In addition, the plant is subject to uncertainty. Special attention is given to the problem of formulating an optimal control problem based on physical insight. The robustness properties of the optimal solution are explored in simulation, by introducing parameter perturbations into the model. Automatic computer tools which greatly simplifies the task of formulating complex dynamic optimization problems are briefly discussed.