Food Processing Machinery

July 13 2026

Potato Chips Processing Line

Ranjan R Case Study, Food Processing Machinery, Plan & Execute

Potato Chips Processing Line

20%

Reduced fabrication time

20%

Reduced material waste

BACKGROUND

A potato chips processing equipment manufacturer needed to optimize production planning, improve resource utilization, and enhance manufacturing efficiency across fabrication, assembly, testing, and project delivery operations. For this, we implemented Opcenter APS.

CHALLENGE

Long manufacturing lead times for customized equipment
Capacity constraints across fabrication and assembly departments
Material availability and inventory management issues
Production bottlenecks affecting assembly and testing throughput
High material wastage and inefficient resource utilization
Limited visibility of project progress and manufacturing workloads
Difficulty meeting customer delivery schedules

APPROACH

Data Integration – Centralized production and resource data.
Capacity Planning – Optimized fabrication, assembly, and testing capacities.
Smart Scheduling – Implemented finite-capacity production scheduling.
Real-Time Monitoring – Tracked production status and workloads.
Continuous Optimization – Improved performance through analytics and planning.

20% Reduction in fabrication cycle time

20% Reduction in overall lead time

30% Improvement in assembly efficiency

Improved Testing performance & throughput

20% Reduction in material waste

Enhanced Inventory management & inventory turns

July 13 2026

Thermal Analysis of Chiller Storage used for Transport

Ranjan R Case Study, Food Processing Machinery, Simulate & Validate

Thermal Analysis of Chiller Storage used for Transport

30.6%

Improvement cooling load

29.6%

Improvement daily energy

BACKGROUND

Chiller storage containers are used to transport temperature-sensitive products such as dairy, meat, fruits, vegetables and pharmaceuticals.

CHALLENGE

Hot spots and cold spots inside the compartment, leading to product deterioration
Cooling efficiency affected due to heat transfer through walls, roof, floor, doors and infiltration
Frequent door openings during loading/unloading leading to temperature rise
High ambient temperature and solar radiation, increasing the cooling load
Inefficient insulation and cooling system resulting in higher energy usage
Need to maintain required temperature range as per regulatory standards

APPROACH

Developed detailed 3D model of the chiller storage container including insulation, doors, vents, evaporator and products
Defined thermal properties of wall panels, insulation (PUF), floor, ceiling and internal loads.
Set boundary conditions for ambient temperature, solar load and infiltration.
Performed transient CFD analysis to study airflow, heat transfer and temperature distribution inside the compartment.
CFD simulation scenarios analyzed
• Steady state (constant ambient)
• Door opening (frequent cycles)
• High ambient conditions Different loading conditions
Optimized insulation thickness, door seal, airflow distribution and evaporator placement to achieve uniform cooling and lower energy consumption.
Simulation results validated with actual test data to ensure accuracy and reliability.

Uniform temperature maintained within the desired range of 0°C to 4°C.

Proper airflow circulation ensured with optimized evaporator placement and vent design.

29.6% Improvement Daily Energy Use (kWh)

28.2% Improvement Peak Power (KW)

30.6% Improvement Cooling Load (KW)

July 13 2026

Thermal Analysis of Bread Making Machine

Ranjan R Case Study, Food Processing Machinery, Simulate & Validate

Thermal Analysis of Bread Making Machine

22%

Reduced energy consumption

18%

Reduced baking time

BACKGROUND

Thermal performance of the baking oven is critical to ensure uniform baking, proper crust formation, soft texture inside and energy efficiency.

CHALLENGE

Non-uniform temperature distribution inside the baking chamber causing inconsistent baking
High energy consumption due to inefficient heat utilization and heat loss
Hot spots & over-baking at some locations while under-baking at others
Longer baking time affecting productivity
Need for optimal airflow and proper insulation to maintain consistent temperature and reduce losses

APPROACH

Developed the oven’s 3D CAD model
Performed CFD analysis for airflow and heat transfer
Conducted thermal analysis for steady state and transient conditions
Evaluated different heater positions, airflow rates and insulation thickness
Optimized design based on temperature uniformity and energy efficiency

Potato Chips Processing Line

Potato Chips Processing Line

20%

20%

BACKGROUND

CHALLENGE

APPROACH

20% Reduction in fabrication cycle time

20% Reduction in overall lead time

30% Improvement in assembly efficiency

Improved Testing performance & throughput

20% Reduction in material waste

Enhanced Inventory management & inventory turns

Thermal Analysis of Chiller Storage used for Transport

Thermal Analysis of Chiller Storage used for Transport

30.6%

29.6%

BACKGROUND

CHALLENGE

APPROACH

Uniform temperature maintained within the desired range of 0°C to 4°C.

Proper airflow circulation ensured with optimized evaporator placement and vent design.

29.6% Improvement Daily Energy Use (kWh)

28.2% Improvement Peak Power (KW)

30.6% Improvement Cooling Load (KW)

Thermal Analysis of Bread Making Machine

Thermal Analysis of Bread Making Machine

22%

18%

BACKGROUND

CHALLENGE

APPROACH

Uniform baking achieved across all zones

22% reduction in energy consumption

18% reduction in baking time

Improved machine reliability & longer component life

Consistent product quality in mass production