An European Detergents major was facing problems on the dosing line of their high volume product. The detergent were delivered in sachets and they were being either over filled or under filled in the dosing and cleaning line.

Axiom was contracted to study and analyze the problem and provide quick solution to address this field problem. The performance of the cleaning nozzle was identified as the potential problem area. This was evaluated using physical measurements on the dosing line. The velocity profile across the nozzle opening was measured under various operating conditions and analyzed

The performance of the nozzle was also evaluated using CFD simulations, the CFD model was then correlated with the physical measurements. This correlated CFD model enabled virtual design changes and performance evaluation which led to quick design modifications

As a part of evaluating different design vectors , the engineer used the lessons learnt in design of extrusion dies which translated to the development of key features of this nozzles. Cross pollination of ideas across verticals was a big driver in arriving at the final solution

• Online velocity measurements in plant
  
• CFD simulation for evaluation of nozzle’s dust cleaning performance
• Complete redesign of seal cleaning nozzle using leanings from extrusion die design
• Development of 3D and 2D CAD models
• Prototype development of nozzles using sand casting process
• Functional testing of the sand cast prototype
• The sensor data was streamed to a PC through a wireless connection. Scale model testing was conducted for a month
• Nozzle assembly assistance in the plant

Result :

• The new nozzle design ensured 100% dust cleaning
• The dosing issues on the line was completely solved
  

Core Competency Leverage: