Digital Twins for Industrial Mixing Systems | BBM
Increased efficiency and significant cost savings through digital simulations and customized solutions.
-50%
85%
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BBM
BBM Maschinenbau GmbH optimized their blow molding processes using the AI-powered StrömungsRaum® simulation from IANUS, achieving significant cost savings and improved production quality.
Solution
By utilizing the StrömungsRaum® platform, BBM was able to optimize material distribution in the spiral distributor, reduce waste, and make production processes more efficient.
Company size
150 employees
Revenue
>20 million EUR
Challenge
BBM Maschinenbau GmbH, specialized in blow molding technology, faced complex challenges. A uniform material distribution in the spiral distributor was essential to ensure high quality standards. However, uneven distributions regularly led to surface defects and increased scrap – costly and inefficient obstacles for production.
The shortage of skilled workers and the high 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 coil distributors, BBM was able to reduce flushing times by 80%, resulting in savings of approximately €14,000 per material change. The threefold reduction of rejects and the possibility to use recyclates without quality degradation highlighted the sustainable added value of the collaboration. With a drastic reduction in processing times—from several days to just a few hours—BBM was able to significantly accelerate its development processes, thereby increasing their efficiency and productivity.
Flushing time reduction by 80%: Savings of around €14,000 per material change
Less rejects: Threefold reduction in rejects due to more homogeneous temperature distribution
Increased recyclate usage: The precise control of dwell times enabled the use of recyclates without loss of quality.
Efficient development: The processing time of the coil distributors was reduced from several days to just a few hours.
Process
With IANUS and the StrömungsRaum® platform, BBM relied on 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 requirements of blow molding technology. In close collaboration, IANUS created precise, parametric models tailored to BBM's tool geometries. Using these AI-driven simulation models, temperature profiles and material distributions were analyzed and optimized in detail. The cloud-based infrastructure and automated workflows significantly reduced the processing times for simulations and allowed for quick adjustments of the process parameters.
Data Analysis and Modeling: BBM provided specific tool geometries that IANUS transformed into customized parametric models, perfectly aligned with the requirements of blow molding technology.
Simulation and Optimization: Using AI-driven simulations, temperature profiles and material distributions in the spiral distributor were analyzed and precisely optimized to achieve the best possible balance.
Automated Analyses: Automated workflows and parallel computations significantly reduced processing time. This enabled rapid adjustments and continuous improvements in production processes.
Conclusion
The partnership between BBM and IANUS demonstrates how digital simulations and AI in blow molding technology can lead to sustainable efficiency improvements and significant cost reductions.
The cloud-based access, customized simulations, and flexible support from IANUS not only enhanced the production quality of BBM but also increased its profitability and competitiveness.
This innovative solution provides an optimal response to rising market demands and supports BBM on its path towards digital transformation.
