FMCG
38% increase in throughput
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Background
Spray drying is energy-intensive, operationally complex and prone to inefficiencies. The efficiency of a spray drying system is governed by a delicate balance of multiple interacting variables.
Challenge
The client’s control systems couldn’t automatically adjust key process settings to account for changes in moving boundary conditions. As a result, moisture levels fluctuated too much, leading to inconsistent product quality and excessive waste from either coagulation or over-drying.
- Existing process controls could not adapt automatically to changing production conditions
- Variability in moisture led to inconsistent product quality
- Inefficiencies caused coagulation or over-drying, resulting in significant material losses
- Shifting boundary conditions created operational instability and reduced overall efficiency
Solution
PurpleSector deployed a customised Dynamic Process Control system and embedded sensors which measure and analyse key variables such as temperature and airflow.
Digital twinning simulations identified optimal settings, and a machine learning algorithm was trained to control and regulate those levels at every stage of the production process, and in real time.
Results
Moisture levels dropped by more than 40%, enhancing quality and consistency. Product wastage was eliminated, and energy consumption reduced by nearly 15% lowering both costs and environmental impact.
Throughput increased by 38%, enabling the client to get more product to market faster. More than 0.7% of revenue was converted into profit.
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We deploy F1™ - derived tools, technologies and techniques to help organisations operate like an F1™ team. Our goal is to build the in-house capability for clients to solve challenges, uncover opportunities and deliver performance gains at race-pace.
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