Solid oxide protonic electrolyte materials make protonic ceramic electrochemical cells (PCECs) viable to be operated at reduced temperatures (400~600 ^oC) because of its high conductivity and low activation energy. Barium zirconate and/or cerate are representative candidates which are mainly synthesized via conventional solid state reaction (SSR) method. Currently, synthesizing a pure phase of BZCYYb4411 in a large batch is still challenging with desired particle size for scaled manufacturing of PCECs. By optimizing and developing the SSR process, we successfully demonstrated large batch fabrication of these powders enabled by micro-sized mediates in the ball milling profiles. It can result in excellent powder quality including high phase purity, and favorable particle size and distribution with demonstration for subsequent cell manufacturing. More importantly, establishing such a protocol of kilogram-scale mass production by shortening the overall fabrication time and increasing the manufacturing efficiency has pronounced implication in the reduction of overall cost and carbon footprint, which is proven by Technoeconomic analysis (TEA) and life cycle assessment (LCA). It represents a critical step for PCEC advancement with serious consideration on supply chain development.