Case Study

July 15 2026

CAE & CFD Analysis for Grain Storage

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

CAE & CFD Analysis for Grain Storage

30%

Reduction in maintenance risk

25%

Improvement structural safety

BACKGROUND

Grain silos and storage bins are critical for preserving grain quality and ensuring structural safety.

CHALLENGE

Structural Safety
Material Stress & Buckling
Grain Flow & Pressure
Temperature & Moisture Control
Aeration Efficiency
Design Optimization
Load Cases Considered
Design Optimization

APPROACH

CAE ANALYSIS (Structural)
- 3D CAD Modeling
- Finite Element Analysis
- Load Cases Considered
- Design Optimization
CFD ANALYSIS(Aeration & Thermal)
- CFD Modeling
- Airflow & Heat Transfer Analysis
- Optimization

25% Improvement in Overall Structural Safety

15% Reduction in Construction Cost

27%Improved Grain Quality & Storage Life

22% Energy Savings in Aeration System

30% Reduction in Maintenance Risk

July 13 2026

Milk to Powder Machine

Ranjan R Case Study, Design & Build, Food Processing Machinery

Milk to Powder Machine

30%

Reduced processing time

20%

Lower energy consumption

BACKGROUND

A dairy processing company required an efficient automated system to convert liquid milk into high-quality milk powder while maintaining nutritional value, reducing moisture content, and improving production consistency.

CHALLENGE

Maintaining uniform drying temperature
Preventing powder lump formation
Reducing moisture content to required standards
Ensuring continuous high- speed production
Minimizing product loss during processing
Achieving energy-efficient operation

APPROACH

Designed automated spray drying system for controlled evaporation
Optimized hot air distribution mechanism for uniform drying
Integrated rotary atomizer/ nozzle system for fine milk particle formation
Performed thermal and airflow simulation analysis
Added automated monitoring for temperature and moisture control
Validated system performance through production trials

98% Moisture removal efficiency

30% Reduction in processing time

20% Lower energy consumption

99% Powder consistency achieved

15% Increase in production capacity

Improved product shelf life and quality stability

July 13 2026

Milk Cream Separator Design & Optimization

Ranjan R Case Study, Design & Build, Food Processing Machinery

Milk Cream Separator Design & Optimization

15%

Reduced
power

15%

Improved cream separation efficiency

BACKGROUND

A dairy equipment manufacturer required the design and optimization of a Milk Cream Separator to improve efficiency, reliability and hygiene. The machine had to operate continuously with consistent performance in dairy processing facilities.

CHALLENGE

Design of high-speed rotating bowl to withstand centrifugal forces
Achieve high separation efficiency without affecting milk quality
Minimize vibration and ensure rotor stability
Maintain food-grade hygiene and easily cleanable design
Optimize weight without compromising strength
Reduce power consumption and maintenance requirements

APPROACH

Developed 3D CAD models of all parts and assemblies
Performed structural analysis (FEA) on critical components
Conducted rotor dynamic analysis to evaluate vibration and stability
Optimized bowl geometry and flow path for better separation efficiency
Validated shaft, bearing and support structure for long life
Designed hygienic product contact parts as per dairy standards
Prepared manufacturing drawings, assembly drawings and BOM

10-15% Improvement in cream separation efficiency

35% Reduction in vibration levels

20-25% Reduction in component weight

15% Reduction in power consumption

July 13 2026

IR Rice Cooker

Ranjan R Case Study, Design & Build, Food Processing Machinery

IR Rice Cooker

20%

Reduced
cooking cycle time

18%

Improvement
heating efficiency

BACKGROUND

Design requirement of Rice cooker of 25KG raw rice.

CHALLENGE

Achieving uniform heating for 25 kg raw rice capacity
Reducing overall cooking cycle time
Maintaining temperature consistency across vessel
Minimizing power consumption during operation
Improving structural stability for continuous industrial use

APPROACH

Designed optimized IR heating chamber layout
Performed 3D CAD modeling and thermal analysis
Optimized reflector and heater placement
Improved insulation design to reduce heat loss
Validated performance through simulation and testing

Achieved uniform heat distribution across cooking vessel

Improved cooking efficiency with optimized heating pattern

Reduced thermal losses through better insulation

Enhanced machine durability and operational reliability

Successful validation for industrial batch cooking

25% reduction in cooking cycle time

18% improvement in heating efficiency

20% reduction in power consumption

July 13 2026

Egg Yolk & White Separation Machine

Ranjan R Case Study, Design & Build, Food Processing Machinery

Egg Yolk & White Separation Machine

25%

Reduced product wastage

35%

Increase processing speed

BACKGROUND

A food processing company required an automated system for precise separation of egg yolk and egg white to improve hygiene, reduce manual handling, and increase production efficiency for bakery and food manufacturing applications.

CHALLENGE

Achieving accurate yolk and white separation
Preventing yolk breakage during processing
Maintaining hygienic food- grade operations
Handling high-speed continuous processing
Reducing product wastage
Ensuring easy cleaning and maintenance

APPROACH

Designed automated egg cracking and separation mechanism
Developed precision separator cups for clean yolk-white division
Integrated conveyor-based egg feeding system
Optimized motion control for synchronized operation
Performed simulation for separator efficiency validation
Added stainless steel hygienic design for food safety compliance

99% Separation accuracy

35% Increase in processing speed

25% Reduction in product wastage

20% Lower manual labor requirement

98% Hygienic processing efficiency

July 13 2026

Design Of Potato Fries Making Machine

Ranjan R Case Study, Design & Build, Food Processing Machinery, Special Purpose Machinery

Design Of Potato Fries Making Machine

20%

Reduced product breakage

20%

Improved production capacity

BACKGROUND

A food processing equipment manufacturer required the design and development of an automated potato fries making machine to improve production capacity, product consistency, and operational efficiency.

CHALLENGE

Achieve uniform fry dimensions for consistent product quality
Minimize product breakage during handling and conveying
Ensure uniform frying and heat distribution
Reduce oil consumption and product oil absorption
Maintain food-grade hygienic design
Increase production throughput
Reduce maintenance requirements and downtime
Optimize machine weight and manufacturing cost

APPROACH

Developed complete 3D CAD models of machine assemblies
Designed feeding, cutting, conveying, frying, and de-oiling systems
Conducted thermal evaluation of fryer chamber
Optimized conveyor and product flow path
Improved oil circulation and filtration arrangement
Reduced component weight through design optimization
Prepared manufacturing drawings, assembly drawings, and BOM

20% Improvement in production capacity

25% Process efficiency

15% Reduced product breakage

20% Product consistency

July 13 2026

Cream Separator Machine

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

Cream Separator Machine

30%

Improvement in planning efficiency

25%

Reduction in schedule changes

20%

Increase in resource utilization

BACKGROUND

A milk cream separator manufacturer needed to optimize production planning, improve resource utilization, and enhance on-time delivery across machining, fabrication, assembly, and testing operations. For this, we implemented Opcenter APS.

CHALLENGE

Manual production planning and scheduling
Managing multiple customer orders and machine variants
Capacity constraints across machining and fabrication departments
Frequent schedule changes due to engineering revisions
Limited visibility of resource availability and workloads
Difficulty achieving on-time manufacturing and delivery targets

APPROACH

Data Integration
Integrated production orders, BOMs, inventory, resources, and project schedules into a centralized planning environment.

Capacity Modeling
Defined machining, fabrication, assembly, balancing, and testing capacities with resource constraints.

Planning & Scheduling
Implemented finite-capacity scheduling and optimized production sequencing.

Monitor & Execute
Enabled real-time production monitoring and schedule tracking.

Continuous Improvement
Utilized analytics and what-if scenario planning to improve production performance.

25% improvement in planning efficiency

20% reduction in schedule changes

15% increase in resource utilization

15% reduction in production bottlenecks

95%+ on-time machine delivery

Improved visibility across the entire production process

July 13 2026

Ice Cream Processing Line

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

Ice Cream Processing Line

25%

Improvement in planning efficiency

20%

Reduction in schedule changes

15%

Increase in resource utilization

BACKGROUND

An ice cream manufacturing line need optimized production planning, resource allocation, and scheduling, for which we implemented Opcenter APS.

CHALLENGE

Manual production scheduling and planning
Managing multiple flavors, stock keeping units, and packaging formats
Capacity constraints across processing and filling lines
Frequent schedule changes due to demand fluctuations
Limited visibility of production resources and workloads
Difficulty achieving on-time production and delivery targets

APPROACH

Data Integration
Integrated production orders, inventory, resources, and demand data into a centralized planning environment.

Capacity Modeling
Defined processing, freezing, filling, and packaging capacities with resource constraints.

Planning & Scheduling
Implemented finite-capacity scheduling and optimized production sequencing.

Monitor & Execute
Enabled real-time schedule monitoring and production tracking.

Continuous Improvement
Used analytics and what-if scenario planning for ongoing optimization.

25% improvement in planning efficiency

20% reduction in schedule changes

15% increase in resource utilization

15% reduction in production bottlenecks

95%+ on-time production delivery

Improved visibility across the entire production process

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)