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Simulations play a central role in the development and optimization of machines. They are used whenever new machines are designed or existing systems must be adapted due to regulatory changes or optimization measures. Simulations allow physical processes to be analyzed in detail. Optimization potential can be identified at an early stage and innovations can be driven forward in a targeted manner. They are used precisely where it is important to make well-founded decisions in the early development phase.
Simulations accompany the engineering process. Ideally, they are actively involved between the mock-up phase and the iFAT. This allows critical aspects to be identified at an early stage and checked in a targeted manner. Traditional test methods such as physical smoke tests or elaborate measurements on prototypes are often time-consuming and costly. In addition, they cannot always be reliably reproduced at an early stage. Simulations, on the other hand, make it possible to run through various scenarios virtually. Physical properties are calculated precisely. Adjustments can be made at an early stage - even before a machine is built or retrofitted. This offers enormous advantages for customers. By identifying optimization potential at an early stage, expensive retrofitting or unnecessary delays can be avoided.
Our machines are already at a very high level of optimization. That's why we focus on the details. Even the smallest adjustments can have a major positive impact on the overall result. We always look at the interactions. How does a component influence neighboring components? We specifically analyze these relationships in the simulation to identify optimization potential
Simulations are particularly important in the pharmaceutical industry. They protect sensitive products from possible contamination or quality impairments. Where products come into contact with machine parts or non-sterile air flows, simulations can reveal problematic flow conditions at an early stage. This avoids expensive reworking and production downtime in later phases and ensures the highest standards in production.
At Optima, simulations accompany every new development, every modification, and every optimization. With customized analyses, simulations provide designers with valuable insights. Using methods such as strength analysis, H2O2 simulations and airflow analysis, mechanical loads, decontamination processes and air flows can be precisely calculated and specifically improved. This makes it possible to design machines more efficiently, sustainably, and safely.
A key advantage of the simulations is their ability to make the invisible visible. Air flows within machines, the precise distribution of hydrogen peroxide during a decontamination process or the temperature distribution in a production plant - all these factors influence the quality and safety of products. But they are not visible to the naked eye. Simulations make it possible to visualize these processes and control them in a targeted manner. This allows us to maximize machine performance and meet customer requirements.
Optima relies on powerful open-source software that is run on high-performance computers at the University of Stuttgart. This enables detailed and precise simulations to be carried out. Optima works closely with the University of Wuppertal to validate these models. Here, real flow data is collected using methods such as Particle Image Velocimetry (PIV) to align the simulations with real measured values and ensure that they accurately reflect the actual conditions.
The potential of simulations is far from exhausted. The goal is to continuously develop the methods and expand the possibilities of the technology. Simulations are far more than just a tool for error analysis - they are a key driver of innovation.
Author
Bernd Horlacher
Team Leader Process & Flow Simulation at Optima Pharma
