Virtual testing of spray shadows, volume flow and cleaning effect with ADVISIM3D

ADVISIM^3D is a fast, simple, resource-efficient 3D cleaning simulation for container and component cleaning in the food, pharmaceutical and manufacturing industries.

Requirement

The hygienic production, storage and delivery of pharmaceutical products, cosmetics and the food industry place high demands on the cleanability of the production areas as well as storage and transport containers. Complex plants with integrated cleaning systems that ensure both product safety and environmental protection are usually required.

Problem

The efficient design of plants ties up enormous resources and is often based solely on the valuable experience and knowledge of engineers. Optimally positioning static and dynamic cleaning nozzles is a major challenge. Thus, cleaning systems are reconfigured several times with the help of extensive analog tests and are often oversized in the end for safety's sake.

Solution

ADVISIM3D reliably simulates industrial spray cleaning processes to detect and realize optimization potentials for planning, construction and operation of professional cleaning environments. It enables the engineer to make valid statements about spray shadows, volume flow distribution and a possibly unsatisfactory cleaning effect, but above all a quick comparison of variants for best resource efficiency.

ADVISIM^3D means digitalizing your expenditure for maximum analog benefit.

Get started today with ADVISIM^3D

Software in use

ADVISIM3D – Your digital assistant

in all phases of system design with integrated parts and surface cleaning

Design

ADVISIM^3Dprovides you with support during the conception of the individual modules and the entire system:

Define and check the type of cleaning system
Plan, test, and adjust selection and positioning of cleaning nozzles to detect spray shadows and oversizing
Determine, check, and adjust cleaning parameters, especially the operating pressure of nozzles
Predict the optimal operating parameters for higher cycle times and lower resource consumption

Implementation and validation

ADVISIM^3D can provide valuable support before and during the commissioning of a plant.

Component manufacturing as well as food, pharmaceutical, and cosmetic production benefit from the design, adjustment, and parameterization of cleaning systems.
Especially during commissioning, ADVISIM 3D in the hands of an experienced engineer provides valuable assistance in process validation and adaptation.
ADVISIM^3Dvirtually simulates most of the iteration steps in cleaning validation to minimize cost operators in the analog world.

Optimization

Existing systems are already part of the production process. Every downtime costs money and resources – which makes the support of ADVISIM 3D all the more valuable in virtual troubleshooting and in finding optimization potentials to minimize disturbances in the production process and to continuously optimize the operating parameters. With ADVISIM^3D:

problem areas can be virtually detected and eliminated if cleaning is not successful enough.
you can quickly and easily adapt the cleaning system to new format sizes or fixtures.
you can optimize your operating parameters to achieve lower cycle times and lower resource consumption.

Amortization

Your digital assistant ADVISIM^3D virtualizes your expenditure with the conception, design, and validation of your spray cleaning systems.

Whether component manufacturing or the internal cleaning of containers in the food, pharmaceutical, or cosmetics industry – the simulation of ADVISIM^3D saves you valuable personnel, time, financial, and, above all, environmental resources.
And with every optimized cleaning process in productive operation, the avoidance of spray shadows and oversizing makes a huge difference thanks to optimal nozzle configuration.

Benefits with ADVISIM3D

Design, layout as well as testing and determination of the ideal dimensioning are far superior to the previous analog process with ADVISIM3D. The digital solution

saves time and manpower.
protects the environment.
enables better cleaning results as more configurations can be tested in less time to identify the optimal balance between product or consumer safety and cleaning intensity

[Translate to English:] Unterschiedliche Reinigungsszenarios wie Innenreinigung von Tanks, Flaschen- oder Getränkekästenreinigung in Waschstraßen, Teilereinigung in Körben etc.

ADVISIM3D Reinigungsszenarien Pharmaindustrie

ADVISIM3D Reinigungsszenarien, Lebensmittelindustrie, Reinigungssimulation

ADVISIM3D Nutzen und Einsatz, Branchen für Anlagendesign

Cleaning scenarios

ADVISIM^3D is a virtualization solution for the realistic simulation of complex spray cleaning systems.

It is suitable for the design and optimization of a wide variety of cleaning scenarios, such as the interior cleaning of containers, fruit, vegetables, bottles, or beverage crates, as well as industrial component cleaning in baskets or washing lines.

Whether static, dynamic, or rotating, nozzles should provide the fluid with the right volume, the required pressure, and at the right angle to the desired point – ADVISIM^3D is your digital assistant for the virtual simulation of almost all nozzle and fluid-based cleaning constellations.

BENEFIT

As a digital assistant to an experienced engineer, ADVISIM^3D unfolds its full technical potential in the resource-efficient design, layout, and validation of industrial spray cleaning systems.

In combination with human expertise about the nature of contaminants, the effect of cleaning media, and the sensible choice and parameterization of nozzles, the virtualization solution supports valid statements about the expected cleaning efficiency in real operation.

But ADVISIM^3D can also support the operative business in management, sales, or customer service and save precious resources.

What ADVISIM^3D saves and improves

Time

Faster design and layout of cleaning systems
Virtual variant comparison
More test runs in less time thanks to virtual simulation
Bidirectional compatibility with CAD programs
Shorter time to market
Less downtime during product changeover
Competitive edge

Environment

Save cleaning fluid, water and wastewater
Thanks to the virtual variant comparison less effort for assembly, removal of assembly marks, and model contamination
Prevention of incorrect dimensioning thanks to optimal system design and resource-efficient layout
Virtual troubleshooting outside the production environment saves setup time and waste

Transparency

Keyword “glass tank”: digitally visualized cleaning process gives the customer more transparency

Documentation

Clean documentation of the optimal cleaning configuration and export as STEP file
Faster and cheaper proof of cleanability for quality assurance and audits
Automated reporting after each cleanability test

Sales

Use as demonstrator tool for sales support

Expertise

Less engineering hours in system design and layout
Use of ADVISIM^3D efficiently as a sales tool
Uninterrupted production

Control

Optimized process and project control

Reliability

Higher calculation and planning reliability in system design and commissioning
Early recognition and consideration of critical cleaning areas

Highlights

Instant display of spray shadows with nozzle placement
Import of complex CAD models in STEP format
Simulation of linear and rotating nozzle motions with user-defined time and velocity
Large catalog of scientifically measured nozzles from numerous manufacturers
Precise simulation of the volume flow distribution over time for meaningful proof of cleanability
Estimation of the cleaning efficiency of a model contamination under the ideal conditions of a scientific laboratory test
Simulation results as color visualization and in report form
Export of the optimal nozzle/cleaning configuration in STEP format for further processing in the CAD program
Intuitive user guidance and up-to-date look & feel

Insertion of a STEP file

A cleaning simulation must be realistic in order to provide valid statements about spray shadows and volume flow distribution. For this purpose ADVISIM^3D imports the container shape or components as a 3D STEP file.

Nozzle selection from a database

The desired nozzle is selected from the nozzle database with up to currently 200 nozzles and then simply placed at the desired location by right clicking.

View selection

Views can be switched on and off as desired via a selection menu. Models, nozzles, and section surfaces can be freely shown or hidden and the viewing direction can be selected and changed as desired.

Possible settings

For the simulation of component cleaning, it is important that the direction, speed, and origin of the movement are freely adjustable.

Simulation parameters

The simulation parameters duration, number of frames per second, and number of steps to be simulated are freely selectable.

Liquid surcharge

The simulation shows the accumulated liquid surcharge over a freely definable period.

Test cleaning effect detect spray shadows

Reporting

The preview mode shows the predicted grouping area with spray shadows and redundancies. The working mode shows the distribution of the applied volume flow.
The simulation mode shows the temporally and spatially resolved volume flow distribution.
The simulation results can be output in PDF format as a report in preview and simulation mode with screenshots of previously defined views.

Requirements

System:

64-bit Windows operating system, Windows 10 or later
Graphics card and graphics driver with OpenGL 4.0 or higher
32 GB RAM
Internet connection
CAD files in STEP-format

Workflow

Import 3D model
Insert nozzles
Start simulation
Export results

Software offer

Software subscription including update
Free software support
Software for installation on any number of computers
Personal consultation
Live webinars, tutorials

Software-subscription
from 4150 EUR net

annually per license

Unlimited installations
1 active user
Including support and updates

Do you have any questions? We are happy to help you. Telephone +49 351 652622

Geschäftsführung sowie Mitarbeiter aus dem Marketing und der Software-Entwicklung

Company

ADVISIM3D is a product and brand of ADVITEC Informatik GmbH, a company that has been managing and consulting complex IT projects for about 30 years.

The software application is based on the SIMKOR research project designed to develop software for performing virtual cleanability tests and simulating complex spray cleaning systems. It was funded by the German Federal Ministry of Education and Research and successfully realized as a cooperative project with the partners Fraunhofer Institute for Process Engineering and Packaging (IVV) Dresden, the Innovation and Simulation Service Festenberg (ISF) and the consortium leader ADVITEC Informatik GmbH.

SIMKOR

ADVISIM^3D is based on SIMKOR, a research project funded by the Federal Ministry of Education and Research to optimize the use of resources in the development of complex spray cleaning systems. SIMKOR was designed and implemented as a cooperation project in order to integrate the Fraunhofer IVV Dresden, ADVITEC Informatik GmbH, the Innovation and Simulation Service Festenberg (ISF), and Pharmatec GmbH as competence partners as closely as possible.

SIMKOR was successfully completed in 2018. The results serve as a basis for the commercial software product ADVISIM^3D from ADVITEC Informatik GmbH.

FRAUNHOFER IVV

The Fraunhofer Institute for Process Engineering and Packaging (IVV) Dresden is the leading research institute in the field of static and dynamic spray cleaning. The institute has many years of practical experience in cleaning technology, especially in the experimental research of cause-effect relationships and in the monitoring and recording of cleaning processes.
The central task of the IVV within the scope of SIMKOR was to collect metrological data as a basis for reliable, realistic prognoses of cleaning efficiency, which take into account not only the direct stream impact but also the draining fluid as a cleaning component.

Innovation and Simulation Service Festenberg

The ISF is a proven simulation specialist for both research and private industry. The ISF contributed to SIMKOR and will continue to contribute its expertise and years of experience in the field of 3D programming and computer-graphic visualization to ADVISIM^3D. The main task is to simulate the physically complex spray cleaning of tanks and parts cleaning as realistically and efficiently as possible. ISF uses computer-graphic illumination techniques because the wetting cones of spray nozzles and the light cones of a point light source correlate mathematically. The greatest challenges to be overcome are the simulation of overspray areas, trickle film, and volume application, as well as cleaning impacts of nozzles on rotating elements.

PHARMATEC GmbH

Since 1993 Pharmatec has stood for complete solutions for the production, distribution, and storage of pharmaceutical high-purity media as well as for trend-setting process technology with automation solutions in the field of pharmaceutical end production. The current subsidiary of Syntegon Technology accompanied both the SIMKOR research project and the development of ADVISIM3D as a valuable source of inspiration and sparring partner. The practical tests under the real conditions of an experienced system manufacturer provided and continue to provide valuable information for the productive use of ADVISIM3D and are essential for the development of a realistic cleaning simulation.

ADVITEC Informatik GmbH

The task of the consortium leader ADVITEC Informatik GmbH within the scope of SIMKOR was, in addition to overall project and beta test coordination, primarily software engineering including IVV real and ISF-virtualization and simulation data.

Since its successful completion in 2018, SIMKOR will be further developed by ADVITEC into the standard industry software ADVISIM3D with a modern UX for the simulation of cleaning processes for production, distribution, and storage facilities in the manufacturing industry and commercially marketed starting in 2020.

ADVITEC Informatik GmbH has many years of product marketing experience in the public and private sectors and is exclusively responsible for the software engineering, sales, and support of ADVISIM3D.

There is magic...

in every beginning, this is also true for technical innovations like ADVISIM3D. On the other hand, a convincing, reliable software tool is pretty much the opposite of magic, namely the result of a long, intensive, and iterative development process. ADVISIM3D would also be the first software to be launched on the market and not need to be explained and improved in order to be more oriented to users’ needs.

ADVITEC therefore provides intensive support in the common interest of manufacturers and users and assists with a hotline for inquiries. Our aspiration: The initial magic will gradually be transformed into the industry standard software for virtual cleaning simulation, which has what it takes to become an indispensable digital engineering assistant.

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