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
• Introduction
• Modeling of Batch Processes
• Modeling and Evaluation of Food Processes
• Debottlenecking of Batch Processes
• Conclusions
INTELLIGEN, INC.
Computer-Aided Process Design and Simulation
INTELLIGEN, INC.
Pertinent Questions
• 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?
• What is the environmental impact of a process?
INTELLIGEN, INC.
The Role of CAPD and Simulation in
Product Development and Commercialization
IDEA GENERATION
Project Screening, Strategic Planning
Development Groups
PROCESS DEVELOPMENT
Process Evaluation, Process Improvements,
Throughput Maximization, Cost Minimization
FACILITY DESIGN
Equipment & Utility Sizing, Plant Optimization,
Flexibility, Environmental Impact Assessment
Development Groups
Process Engineering
Corporate Environmental
Manufacturing
MANUFACTURING
Cost Estimating, Process Scheduling,
Debottlenecking, Cost Minimization
Manufacturing
INTELLIGEN, INC.
The Pro-Designer Family
of Computer-Aided Process Design and Simulation Tools
SuperPro Designer
BioPro Designer
BatchPro Designer
WaterPro Designer
EnviroPro Designer
Biotechnology
Food Processing
Synthetic
Pharmaceuticals
Specialty Chemicals
AgriChemicals
Water Purification for
Pharmaceuticals,
Semiconductor Industries,
Electric Utilities, etc.
Wastewater Treatment
Air Pollution Control
INTELLIGEN, INC.
Modeling of Batch Processes
INTELLIGEN, INC.
Intuitive User Interface
Unit Procedures and Operations
Right-Click
Context Sensitive Menu
INTELLIGEN, INC.
Assigning Operations to a Unit Procedure
INTELLIGEN, INC.
Flexible Operation Models
INTELLIGEN, INC.
Operations Gantt Chart
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Equipment Utilization Chart
INTELLIGEN, INC.
Resource Demand Chart
INTELLIGEN, INC.
Modeling and Evaluation
of Food Manufacturing Processes
Integrated Dairy Plant
INTELLIGEN, INC.
Raw Material Requirements
Annual Production (kg)
Cheese
Butter
WPC
Ethanol
70,700,000
2,960,000
7,000,000
9,234,000
INTELLIGEN, INC.
Environmental Impact Assessment
Component
Name
Anions
Cations
Lactose
Water
Yeast
Plant Total
Compound
Fat & Protein
Lactose
Water
TOTAL
IN
(kg/h)
OUT AS
LIQUID WASTE
(kg/h)
333.3
250.0
4,083.3
72,666.7
380.0
308.1
231.1
381.2
32,139.2
723.1
100,402.5
34,298.8
Utilization (%)
100
90
44
INTELLIGEN, INC.
Environmental Stream Properties
INTELLIGEN, INC.
Project Economic Evaluation - Summary
INTELLIGEN, INC.
Cash Flow Analysis
INTELLIGEN, INC.
Cost Analysis - Cheese Making Section
INTELLIGEN, INC.
Cost Analysis - Breakdown Per Section
INTELLIGEN, INC.
Product Formulation & Packaging
Solids Handling
Transportation
INTELLIGEN, INC.
Throughput Analysis
and Debottlenecking Theory
INTELLIGEN, INC.
Fully Functional Demo of SuperPro
Available on Website
www.intelligen.com