tkh activity unauthorized changes at customers site (fgp-205)
TRANSCRIPT
Implementation of HPC at Tetra Pak
Ulf Lindblad Tetra Pak,
New trend in CFD II
DANSIS Seminar
2014-09-24
High Performance Computing
The CAE world is in transition. From components analysis to system analysis. From
simplification to realism. This is true for traditional CAE heavy industries as well as for
other industries like e.g. the consumer goods industry.
“Realistic simulation gives us confidence that we will always be able to
costeffectively provide product quality to our customers anywhere in the
world market.”
Dr. Simon Shi, Senior Packaging Engineer,
Global Innovation &Technology Centre,
Coca-Cola Beverage Co. Ltd
“Moving off the desktop and on to HPC systems…was a turning
point for Whirlpool”
Tom Gielda, Engineering Director, Whirlpool Corporation
And HPC is the enabler…
Simulation of clothes in a washing machine
The HPC turning point at Tetra Pak Aseptic System Design with virtual prototypes
HPC=High Performing Cows
High Performing Cows
Increased capacity of
each core cow!
Parallell processing
cluster of cows!
Milk history
“A package should save more than it costs” Ruben Rausing
1946:
Infant mortality rate in New York city:
“ The most beautiful realisation of a mathematical idea I’ve ever seen” Niels Bohr
1878: Gustaf de Laval invents the separator
and founds Alfa Laval (now Tetra Pak)
► A sterilised food product stream and a sterilised packaging
material stream are brought together in a sterile
environment
1961 Tetra Pak pioneers aseptic packaging
Product stream
(sterilised before FM)
Packaging material
(Sterilised in FM)
Package
► A sterilised food product stream and a sterilised packaging
material stream are brought together in a sterile
environment
1961 Tetra Pak pioneers aseptic packaging
Product stream
(sterilised before FM)
Packaging material
(Sterilised in FM)
Package
21rst century Glass is out but bottles are coming back!
1963:
1884:
2011:
What does it take to go from brick to bottle?
.. and keep it aseptic?
For preformed package systems FDA directly address the airflow
Pe
roxid
e
Ste
rile
air
Pro
du
ct
Se
ale
r
Air
Pe
roxid
e
Ste
rile
air
Pro
du
ct
Pe
roxid
e
Ste
rile
air
Pro
du
ct
Se
ale
r
Air
Figure 1. Aseptic section of a filler. Sterile air flowing past the preformed cups creates
the boundary at the top of the cups for the asetic zone.
Designed and validated airflow
protecting the packages and
the aseptic zone.
”A system like this requires careful
validation work by the manufacturer since
there is no physical barrier”
John Larkin, Pharma+Food International 2000
“the concept of the aseptic zone”
“establish and maintain sterility”
“dialog during the design stage of a process”
“the barrier is the sterile air flow pattern”
Moore quotes from Larkin, Pharma+Food International 2000
Conceptual
Aseptic
System
Design!
Event driven
design &
worst
condition
identification!
“Line jam, line stoppages”
“operator intervention”
“alarm handling” “all operational states”
“the system must never operate at worse
conditions than validated settings”
The virtual prototype - a huge computational model
• Standard case: 150 million cells
• 2000 machine configurations tested in 2 years
• Design loop of 1 week
Full virtual model of filling machine
-simulating aseptic performance
Dynamic mesh of 100 million cells
Gassing Venting
Active nozzle
Gassing and
Venting
Active Nozzle
Package
Active Nozzle enables a robust and optimised package sterilisation
process as well as enables an aseptic zone protection
Full virtual model of filling machine
-cluster of models
15 sub models and 10 machine sequences
LES/VOF
URANS/dynamic mesh
Spray
Evaporation
Particle load on
packaging material
Supply systems
External cleaning
Cap/neck-heating
How do we want the transient flow to interact in filling station 2-4?
Liquid jet plunge
Combi-1.5, 3rd Station
Air Entrapment in Combi-1.5 (4th st.)
Air Volume : 10.46 ml
dydxxVol ..2
LES with indexing
LES with indexing
A6 filling machine – Bulk flow of sterile air
► The flow barrier is created by using a
bulk flow of sterile air.
Aseptic zone
Flow barrier
240 cores => 1 simulation day is 1 machine second
OVERSET -for filling machine virtual prototype
Next step of technology for fillers with OVERSET -scaling challenge
0
20
40
60
80
100
120
0 5 10 15 20 25 30 35
CP
U T
ime p
er
tim
e s
tep (
s)
Number of (overset) packages
Linear scaling up to 30 packages
Background mesh 15 million cells
5 days computation on 240 cores for a filling machine (submodule)
=> Possible to integrate into designloops
The original Tetra Pak idea on aseptic packaging
Product stream
(sterilised before FM)
Packaging material
(Sterilised in FM)
Package
Andreas Söderström Effects Researcher at Weta Digital
► Constant product flow from filling
pipe.
► Transient product flow in the bottom
end, using abaqus model to
determine of flow rate.
► Free fluid surface (VOF)
► Rigid cylinder shaped walls, moving
with a transient speed.
► Floater (1 DOF) with overset
The great Challenge: FSI models of the tube
Boundary
fluid model
Qstr(t)
Qfp(t)
Free fluid
fluid surface,
Wall velocity,
v(t)
Pressure
measurements
ove
rse
t
…that we do less physical testing
Thank you for listening! Next time we meet I hope I can tell you:
… and that we have cracked the tube model!