The production of synthetic fuels and chemicals from solar energy and abundant reagents offers a promising pathway to a sustainable fuel economy and chemical industry. For the production of hydrogen, photoelectrochemical or integrated photovoltaic and electrolysis devices have demonstrated outstanding performance at the lab scale, but there remains a lack of larger-scale on-sun demonstrations (>100 W). Here we present the successful scaling of a thermally integrated photoelectrochemical device—utilizing concentrated solar irradiation—to a kW-scale pilot plant capable of co-generation of hydrogen and heat. A solar-to-hydrogen device-level efficiency of greater than 20% at an H2 production rate of >2.0 kW (>0.8 g min −1) is achieved. A validated model-based optimization highlights the dominant energetic losses and predicts straightforward strategies to improve the system-level efficiency of >5.5% towards the device-level efficiency. We identify solutions to the key technological challenges, control and operation strategies and discuss the future outlook of this emerging technology.