Process Simulation

From the multitude of ways to improve your facility, process simulation can find the most cost-effective option.

Process Simulation can add value throughout the life-cycle of your facility: from master planning through start-up, de-bottlenecking and even day-to-day operations.

Process simulation is a computer representation of a unit operation, a single process train or an entire manufacturing plant. Because it is developed on a computer, you can quickly study process alternatives before risking capital expenditures. Our process simulation experts will work with you to construct an appropriate model, validate the model and conduct case studies. We provide training so you can use the model to enhance throughput, reduce costs, or study potential changes to your process.

CRB has no allegiance to any particular software package – we use the best commercially available tools for your application or develop custom tools if needed.

Chances are good that CRB has experience executing simulation projects for a process just like yours. Whether it is a quick capacity analysis, a de-bottlenecking study or a complete design for a new Greenfield manufacturing plant, CRB will build an efficient model to find the answers for your success!

Master Planning – Lower capital cost and operating costs by creating a dynamic model that represents your manufacturing process
  • Review your business plan and manufacturing objectives
  • Simulate each design scenario using your business plan as a guide
  • Produce a lean design and enable lean operations
  • Create faster and easier master plan updates as the market forecast changes
Facility Design - Evaluate process options to find the most economical plant design
  • Reduce Risk – Identify risk of under-performance and risk of overdesign
  • Improved Designs – Study many design alternatives in less time
  • Number and Size of Process and Support Equipment
  • Design Data Repository – Keep all design parameters in ONE place: the model
  • Staffing Requirements
  • Production Scheduling
  • Utility Capacity Design
  • Clean-in-Place (CIP)
  • Waste Handling System Design
  • Right-sizing of Staging Spaces
De-Bottlenecking - Find the most cost effective method to get more product from an existing facility
  • Maximum Facility Throughput
  • Process and Equipment Bottlenecks
  • Staffing and Utility Restrictions
  • Scheduling Constraints
  • Reduction of Work-In-Process
  • Effect of Process Variability and Rework
Operations Improvement - Speed plant response time and reduce operating costs
  • Use a process model in parallel with your plant
  • Prediction of batch completion times
  • Respond better to equipment failure and market demands
  • Production scheduling
  • Improve communication
  • Sensitivity analysis
  • Layout improvements
  • Improved compliance