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Improving Cooking Flow Uniformity
Confidential Client
The first step was to create a 3D model from scratch with all the necessary components for the simulation.
The idea was to have a digital twin to understand how the flow is behaving inside the tunnel. To obtain results faster, the CFD model was simplified with hot air, giving an idea of the flow dynamics inside the tunnel.
We were able to understand and quantify important aspects impacting the process, such as the flow direction, contact time, and residence time among others. With the new understanding of the dynamics in the process, a few ideas were proposed and digitally tested, comparing them against the initial model.
With the use of CFD tools and statistics, we analyzed and quantified the impact of each proposed solution, to prioritize and select the options. In the picture below, the chart guides the analysis process by showing an increase in the green bars and a reduction on the red bars, when comparing them to the initial model in gray, behind the color bars.
The chart below compares the residence time between one of the options proposed (blue) and the current system (gray, in the back). The residence time is increased when implementing a solution proposed, which allows for increased contact time, helping the process.
After testing multiple options and developing additional alternatives based on analysis, a list of improvements was put together to increase the uniformity in the tunnel. The use of statistical tools with CFD techniques assisted greatly in the analysis and selection process, identifying the options with most impact.
Thanks to CFD, improvements were identified in a shorter time frame and with less cost than when compared to physical testing, without risking negative impact to the product.
With the newly gained insight, the client has deeper understanding of the process inside the tunnel, sparking additional ideas for improvement that can potentially extrapolate to other areas on site.
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