14. AKPS Meeting: Simulation Techniques For Process And Logistics

On April 10, 2025, the 14th meeting of the Process Simulation Working Group took place in Hanau. It was hosted by the renowned German simulation service provider SimPlan AG.

A Fairytale-Like Start

Twenty-three interested experts from the fields of chemistry, pharmaceuticals, food, and engineering had gathered for the working group meeting on Thursday, April 10, 2025. On Wednesday evening, we met for a nice kickoff in the city center of Hanau, experiencing a fairytale-like start – we were led on the trail of the world-famous Brothers Grimm, who were born in Hanau; the evening ended in a traditional tavern with a relaxed get-together.

The actual meeting of the Process Simulation Working Group on the following Thursday had been chosen to focus on Simulation Techniques For Process And Logistics. In the morning, a keynote by the host set our thematic framework.

The working group effortlessly managed the thematic transition from fairy-tale tradition to high-tech modernity with the help of practical presentations that examined the topic of Simulation Techniques For Process And Logistics from a productional perspective. Even more presentations followed in the afternoon, before our proven World-Café-format workshop focused on the participants’ views on the current use, challenges, and applications of simulation in the area of process and logistics.

Keynote: From the classic value stream process to the fluid application level

Stephan Stauber (SimPlan AG)

Stephan Stauber provided a brief overview of Lean Management methods and then introduced the value stream analysis method. This identifies bottlenecks, waste, and improvement potential, and serves as the basis for optimizations. SimVSM is a tool developed by SimPlan that implements a fully digital approach to value stream analysis as a web app and integrates with simulation. Furthermore, Stephan discussed the challenges of implementing fluid value streams and provided a live demonstration of the tool using an example process.

Presentation 2: Predicting microbiological quality using material flow simulation and biological growth models

Tim Schneider (Bayerische Milchindustrie eG (BMI))

Tim Schneider provided an overview of the value chain starting from cow’s milk, and particularly from whey, which is separated and marketed by BMI into various whey proteins, milk sugar, and other substances. Microbiological quality is of great importance here, and its influencing factors are the initial microbial load, temperature, storage duration, and sugar concentration. During the process, starting from whey, the microbial load initially decreases through heating, then increases through storage and multi-stage ultrafiltration; while the permeate has a very low microbial load, microbes are concentrated on the retentate side. Certain heuristics can be derived for a possible low microbial count, such as prioritizing retentate over permeate streams in further processing. By simulation with INOSIM, among other things, an average processing time and storage time for different plant configurations could be predicted. This supports BMI in planning a plant optimized for the best possible microbiological quality.

Presentation 3: Discrete event simulation of a cleaning system with SimPy

Andreas Fischer (Biotest AG)

Andreas Fischer presented a simulation-based approach. The question was whether the capacity of a cleaning machine for process equipment (dishwasher) is sufficient for increasing numbers of production batches per week. A production schedule from SchedulePro was used to create a list of equipment in/out events (e.g., pharmaceutical hammer). A number of restrictions must be observed: Clean Time and Dirty Hold Time, loading patterns of the cleaning machine. The system represents an interesting optimization problem: if there is too little equipment, the process must wait, if there is too much equipment, it must be constantly cleaned unused, for example, because the Clean Hold Time has expired, and this requires more cleaning capacity.

The Python-based freeware SimPy (Discrete-Event Simulator) was chosen to simulate the system. This tool is purely code-based and only allows limited creation of custom classes. Simulations of various scenarios confirmed that the cleaning system can handle Ramp-Up, and recommendations for action were derived.

Presentation 4: Integrated recipe–based simulation of production processes and intra– and inter–logistics

Dominik Aubel (INOSIM GmbH)

Dominik Aubel provided insights into an ongoing project for the joint simulation of process and logistics with INOSIM Packaged Goods: Raw materials and packaging materials are transported from a remote large warehouse to the production site just-in-time by truck. Unused materials and packaged products are re-stored. Numerous secondary conditions and heuristics must be observed to represent the challenges of real-world operation. The project involves the coupling of several tools: An APS tool creates a production plan, which is used in INOSIM with additional data (e.g., inventory, intermediate storage, recipe parameters) to test the feasibility of the production plan and generate utilization-optimized transport bills of materials. The simulation of logistics processes is made possible by the INOSIM Packaged Goods Add-on.

Presentation 5: Combining batch production and discrete manufacturing in fill and finish processes

Danylo Spitsyn (Sigma Process & Automation GmbH)

Danylo Spitsyn presented a Fill & Finish simulation project aimed at determining whether the target capacity of blood plasma product production could be achieved with an initial design. The model follows the process through multiple changes, from batch production to discrete storage and manufacturing and back. INOSIM Software with the Packaged Goods Add-On was used so that the logistics processes could be mapped in a recipe-based manner using modules. The model is modular so that new products can be easily compiled into a matrix. The analysis focused on pallet storage spaces over time (simulation period: 1 year) and equipment utilization. The analysis of the parking spaces shows that they were only barely sufficient in some areas (94 out of 96 occupied during peak hours). In the future, the model should be expanded to include the detailed upstream batch production process and limitations, such as in the form of personal staff.

Demonstrator Workshop

Demonstrators were set up at three stations for SimVSM, INOSIM Insight with Packaged Goods Add-on, Anylogic, and Plant Simulation with 3D glasses. At the stations, you were able to discuss detailed questions with a hot cup of coffee in hand, and even try out a VR-style simulation at the last station. The feedback from the working group meeting was collected on the flip chart and discussed at the end of the meeting.

Evaluation

At the end of the meeting, feedback from the participants was collected using three guiding questions:

INOSIM, as the organizer of the working group, and SimPlan, the host, would like to thank everyone who participated for their very valuable feedback. In the future, the working group meetings should focus even more on live demos to promote discussion of real practical challenges.

Outlook for the next meeting

The next Process Simulation Working Group is scheduled for September 2025. You will receive more detailed information soon here on the INOSIM Homepage as well as on the (German) Homepage of the Working Group. We are pleased to receive your registration and look forward to inviting you to the next meeting!

Do you have any questions or would like to know more about this topic? Please contact us.