Digital Twins for Industrial Mixing Systems | BBM
Increased efficiency and significant cost savings through digital simulations and tailored solutions.
-50%
85%
-66%
BBM
BBM Maschinenbau GmbH optimized its blow molding processes using the AI-powered StrömungsRaum® simulation from IANUS, achieving significant savings and improved production quality.
Solution
Through the use of the StrömungsRaum® platform, BBM was able to optimize material distribution in the spiral distributor, reduce scrap, and streamline production processes.
Company size
150 employees
Revenue
>20 million EUR
Challenge
BBM Maschinenbau GmbH, specialized in blow molding technology, faced complex challenges. Consistent material distribution in the spiral distributor was essential to ensure high-quality standards. However, imbalanced distributions regularly resulted in surface defects and increased scrap – costly and inefficient obstacles in production.
The shortage of skilled workers and the extensive effort required for conventional simulations further complicated the optimization processes. BBM needed an innovative solution to improve thermal and volumetric balance while simultaneously reducing resource consumption.
Result
The results speak for themselves: By optimizing the helical distributors, BBM was able to reduce flushing times by 50%, resulting in savings of approximately €14,000 per material change. The threefold reduction in waste and the ability to use recyclates without quality loss demonstrated the sustainable added value of the collaboration. With a drastic reduction in processing times – from several days to just a few hours – BBM significantly accelerated its development processes, thereby increasing their efficiency and productivity.
50% reduction in flushing time: Savings of around €14,000 per material change
Less waste: Threefold reduction in waste through more homogeneous temperature distribution
Increased use of recyclates: Precise control of residence times enabled the use of recyclates without quality diminution.
Efficient development: The processing time of the helical distributors could be shortened from several days to a few hours.
Process
With IANUS and the StrömungsRaum® platform, BBM utilized a combination of cutting-edge CFD technology and AI-driven simulation. The customized models and cloud-based workflows enabled BBM to efficiently meet the specific demands of blow molding technology. In close collaboration, IANUS created precise, parametric models tailored to BBM's tool geometries. Using these AI-powered simulation models, temperature profiles and material distributions were thoroughly analyzed and optimized. The cloud-based infrastructure and automated workflows significantly reduced the processing times for simulations and allowed for rapid adjustment of process parameters.
Data Analysis and Modeling: BBM provided specific tool geometries, which IANUS translated into customized parametric models, perfectly tuned to the requirements of blow molding technology.
Simulation and Optimization: Using AI-driven simulations, temperature profiles and material distributions in the helical distributor were thoroughly analyzed and precisely optimized to achieve the best possible balance.
Automated Analyses: Through automated workflows and parallel computations, processing time was significantly reduced. This enabled quick adjustments and continuous improvements in production processes.
Conclusion
The partnership between BBM and IANUS highlights how digital simulations and AI in blow molding technology can result in sustainable efficiency increases and significant cost reductions.
The cloud-based access, tailored simulations, and flexible support from IANUS not only enhanced BBM's production quality but also increased profitability and competitiveness.
This innovative solution provides an optimal response to increasing market demands and supports BBM on its journey to digital transformation.
