Pharmaceutical
Food Products Division Institute of Food Sciences and Technologies
Product Development Center Engineering Group
Ms. Sumi Yamazaki, Mr. Kazuaki Shibuki, Mr. Takeshi Nishinomiya
Most of our products consist of “powders”, such as seasonings, soups etc. We are working on particles design to enhance the function of the powder and the technology to control the physical properties of the powder for a better product, but in fact the behavior of powder is quite tricky. For example, if liquids are mixed, basically they are maintained at a homogeneous mixture state. Whereas for powders, it is possible for segregation to occur. As a result, the powders may not be mixed evenly and the product might need to be discarded.
Experiments are carried out in a small scale to find the solution for this issue, but it may not work well when it is scaled up for an actual machine. As a result, the experiments have to be conducted all over again, resulting in a waste of time and raw materials for the trial and error process.
At the time when I was looking for a more effective way to solve this issue, I have learned about powder simulation technology at an academic conference. With the guidance of Dr. Mikio Sakai (Full Professor at System Resilience Engineering Research Center, The University of Tokyo), we considered the applicability of the simulation software to our assignment for a year. As a result, the powder simulation software iGRAF was introduced. Simulation software from other companies were also considered but iGRAF impressed us with its simple and intuitive operational method.
Other companies provided trial version and also trainings but it seemed difficult to set the simulation parameters or run the software without relying on them. On the other hand, iGRAF can be easily used by learning the software tutorials. This is why iGRAF is chosen.
The common processes of various powders are mixing, discharging and filling. We have started with the analysis of storing and discharging process of a hopper.
The powders that we are using are smaller than 1mm. With the simulation, we do not expect that the phenomenon to be reproduced perfectly as extremely difficult calculations are needed in order to use the original particle size. For example, cases A, B and C with different conditions are simulated to find the worst condition. If the process can be practically reproduced to find the worst condition, two-thirds of the cost of stopping the production line for testing purpose can be reduced. This is the most significant benefit of this software.
Also, if devices with different shapes are to be tested, it takes several months to produce the devices. Even the test devices are ready, experiments and analysis require time, too. With iGRAF, however, the results can be obtained within a week. Time reduction is also one of the notable benefits of this software.
It is known to be difficult to calculate with the actual size of the particle, but we would like to accumulate the know-how of the simulation in order to overcome it.
One of the ways to utilize the software is to solve the problems arise from the manufacturing site. Besides, we can accumulate the basic knowledge of the optimal operation conditions of the equipment that we are using. Although repeating the tests by using equipment is common in the industry, wouldn’t it be better to do it at a lower cost? In other words, the decisions based on experiment experiences can be replaced by the physical theories.
Powdering Process Engineering Sales Dept.
Plant Engineering & Machinery Division
Dr. Changhwa Han, Ms. Muki Sun
As part of the Powder Process Technology Sales Department I belong to, we handle equipment for mixing, grinding, and drying processes. We not only provide equipment for manufacturers dealing with a wide range of powder materials, resins, and chemicals, but also propose process solutions.
Until now, we evaluated equipment performance through testing at our company’s test center, which relied heavily on experience. However, this approach took time due to the need for trial and error and adjusting conditions. To address these challenges, we began considering the introduction of simulation software that could provide predictive results without the need for experiments, leading to cost savings.
When we conducted simulations using iGRAF for twin screw continuous kneader , “KRC Kneader” and observed the actual behavior and were impressed by speed of calculations. Personally, I found iGRAF very user-friendly and realized that it could help solve our company’s challenges. Therefore, we decided to implement it.
Performance of Twin Screw Continuous Kneader
Based on the simulation results from iGRAF, we designed and manufactured a new paddle shape and confirmed it through visualization tests. The observed behavior matched the predicted results from the simulation, which is a significant achievement. We believe that iGRAF will become an essential tool for paddle design in the future.
Additionally, iGRAF offers high computational accuracy and the ability to display results in 3D animations, which is attractive to both us and our customers. When we show the simulation results to our customers and explain how we use iGRAF to determine paddle designs, they easily understood and are satisfied.
Moving forward, we plan to create a database of the effects of mixing conditions and residence time on the mixing state of the materials in our twin screw continuous kneader “KRC Kneader”. We want to utilize this data for paddle selection before testing. Furthermore, we aim to leverage iGRAF’s simulation capabilities for fluidized bed drying design. Our next step would be to apply it to grinding machines and gradually expand its usage.
Researcher, Mineral Resources Research Group
Institute for Geo-Resources and Environment
Dr. Yuki Tsunazawa
Mineral processing known as ore dressing, involves crushing ore obtained from mines and separating valuable minerals from gangue minerals. Many of these processes currently rely on empirical rules. By utilizing particle simulation in mineral processing, the behavior of particles within the equipment can be visualized, leading to the development of efficient processes. We introduced iGRAF, a particle simulation software, which we believed could address our challenges, leading to its implementation.
iGRAF’s strength lies in its ability to calculate the behavior of particles in complex-shaped equipment, a feature unique to iGRAF among other powder simulation software. It enables coupled analysis involving complex interactions between solids, gases, and liquids, which is not readily available in other software.
Furthermore, iGRAF is based on physics models developed in Prof. Sakai’s laboratory and has been published in international scientific journals. The validity of the models ensures confidence in the results and allows users to understand how the calculations are performed.
Simulation of Pot Blender
We had many aspects of particle separation, involving different densities and shapes, that were still reliant on empirical rules. However, visualizing them using iGRAF enabled us to identify separation mechanisms and optimal equipment conditions. Additionally, iGRAF helped us uncover the mixing mechanism of a blending device called a pot blender, and these research findings have been accepted and published in international scientific journals.
In terms of usability, we found iGRAF to be user-friendly even for beginners. It seamlessly handles parameter input, analysis, extraction of necessary data from analysis results files, and processing them to achieve desired outcomes.