Digital Magazine

For over forty years, we have specialized in designing and manufacturing critical food contact components. This extensive experience has enabled us to develop in-depth expertise in the Aseptic Food sector, an area characterized by stringent standards, and to gain recognition from leading companies worldwide.

In addition to Ecor International’s specialization in producing safety- and health-critical mechanical components for food contact applications, we leverage the engineering expertise of Il Sentiero International Campus research center. This collaboration allows us to excel in Rapid Design and Prototyping, Numerical Simulation, Reliability Engineering, Surface Engineering, and Additive Manufacturing. Our product range includes test rigs, electromechanical modules, and automated machines, all rigorously tested for performance by experts at Il Sentiero International Campus. Our research efforts are always directed towards achieving industrial objectives, such as enhancing performance and ensuring food safety.

The objectives of designing an automatic food processing and packaging plant include:

• increasing hourly output capacity,
• reducing operating costs and machinery’s environmental impact,
• introducing innovative cleaning and aseptic systems for the machines.

In this case study, we will explore how Il Sentiero International Campus tackled these challenges by focusing on key objectives.
The design process started with identifying the client’s needs, followed by a collaborative co-design phase. Subsequently technical requirements and their feasibility were analyzed and alternative solutions to address any critical issues were proposed. This initial dialogue facilitated the refinement of technical details and the establishment of a shared vision based on efficiency, cost, and performance criteria.

The next phase entailed prototyping, using a combination of hardware and virtual technologies, including numerical simulation and digital twin. A cutting-edge approach, pioneered at the research center, involved generating a virtual numerical model of the machine to predict its behavior and estimate long-term productivity. Concurrently, sensors were deployed on an actual machine, with the results aiding in calibrating and refining the numerical model.

As a result of these actions, the refined numerical model effectively transformed into a digital twin, enabling the determination of the maximum stresses that various machine components would endure during operation. This achievement was made swiftly and at a minimal cost.

The numerical data obtained was utilized to size confined test rigs optimally on the specific areas of interest of the machine, emphasizing stress, load, vibration, and durability tests. This led to substantial cost savings for the customer and an improved accuracy of the results.

This case study illustrates how design and prototyping, driven by innovative technologies and close collaboration with the customer, can result in significant enhancements in efficiency, cost reduction and environmental sustainability within complex industrial sectors like food packaging.

The complete case study was published in the May issue of Meccanica Oggi magazine.