Bridging the Gap: Simulation Meets Reality with Remarkable Accuracy

Powdering Process Engineering Sales Dept.
Plant Engineering & Machinery Division
Dr. Changhwa Han, Ms. Muki Sun

Qualitative Evaluation and Cost Reduction

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

Successfully Designed and Manufactured a New Paddle

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.