optimization of food and pharmaceutical processes via computer-aided process design and simulation...

Optimization of Food and Pharmaceutical Processes via

Computer-Aided Process Design and Simulation

Presented by

Demetri Petrides

INTELLIGEN, INC.Simulation and Design Tools

for the Process and Environmental Industries

Outline

INTELLIGEN, INC.

• Introduction

• Modeling of Batch Processes

• Modeling and Evaluation of Food Processes

• Debottlenecking of Batch Processes

• Conclusions

Computer-Aided Process Design and Simulation

INTELLIGEN, INC.

• How much would it cost to make a kilo of product?

• Which process is better for making this product? A or B?

• How much product can I make in this plant?

• How do I increase the current throughput?

Pertinent Questions

INTELLIGEN, INC.

• What is the environmental impact of a process?

IDEA GENERATIONProject Screening, Strategic Planning

PROCESS DEVELOPMENTProcess Evaluation, Process Improvements,Throughput Maximization, Cost Minimization

FACILITY DESIGNEquipment & Utility Sizing, Plant Optimization,Flexibility, Environmental Impact Assessment

MANUFACTURINGCost Estimating, Process Scheduling,

Debottlenecking, Cost Minimization

Development Groups

Development GroupsProcess EngineeringCorporate EnvironmentalManufacturing

Manufacturing

The Role of CAPD and Simulation inProduct Development and Commercialization

INTELLIGEN, INC.

The Pro-Designer Familyof Computer-Aided Process Design and Simulation Tools

BioPro Designer

INTELLIGEN, INC.

SuperPro Designer

BatchPro Designer

WaterPro Designer

EnviroPro Designer

BiotechnologyFood Processing

Synthetic PharmaceuticalsSpecialty ChemicalsAgriChemicals

Water Purification forPharmaceuticals,Semiconductor Industries,Electric Utilities, etc.

Wastewater TreatmentAir Pollution Control

INTELLIGEN, INC.

Modeling of Batch Processes

Intuitive User Interface

Unit Procedures and Operations

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Context Sensitive Menu

Right-Click

Assigning Operations to a Unit Procedure

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Flexible Operation Models

INTELLIGEN, INC.

Operations Gantt Chart

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Equipment Utilization Chart

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Resource Demand Chart

INTELLIGEN, INC.

Modeling and Evaluationof Food Manufacturing Processes

Integrated Dairy Plant

INTELLIGEN, INC.

Raw Material Requirements

INTELLIGEN, INC.

Annual Production (kg)

70,700,000 2,960,000 7,000,000 9,234,000

CheeseButterWPCEthanol

Environmental Impact Assessment

INTELLIGEN, INC.

Component TOTAL OUT AS Name IN LIQUID WASTE (kg/h) (kg/h)

Anions 333.3 308.1 Cations 250.0 231.1 Lactose 4,083.3 381.2 Water 72,666.7 32,139.2 Yeast 380.0 723.1

Plant Total 100,402.5 34,298.8

Compound Utilization (%)

Fat & ProteinLactoseWater

100 90 44

Environmental Stream Properties

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Project Economic Evaluation - Summary

INTELLIGEN, INC.

Cash Flow Analysis

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Cost Analysis - Cheese Making Section

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Cost Analysis - Breakdown Per Section

INTELLIGEN, INC.

INTELLIGEN, INC.

Product Formulation & Packaging

Solids Handling

Transportation

Throughput Analysis and Debottlenecking Theory

INTELLIGEN, INC.

Fully Functional Demo of SuperProAvailable on Website

www.intelligen.com