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Simulation in the Consumer Products Industry: Assessing the role of physics-based simulation in realizing a comprehensive digital twin

In the consumer products industry, consumers are now the primary influencers in the innovation process. As such, manufacturers must keep up with the newest trends while adapting their enterprises to become faster and more flexible while maintaining the highest levels of quality and security to deliver the increasingly complex and personalized products their customers demand.

Meeting these demands requires a holistic approach to product design and manufacturing comprised of a comprehensive digital twin of the product, production and performance.

This paper investigates the role of physics-based models -- such as those from CFD, DEM, FEA and system simulation -- in realizing the full potential of simulation in the consumer products industry.

Simulation provides a path toward efficiency and profitability in the increasingly complex world of consumer products

The consumer products and cosmetics industries involve highly complex physico-chemical phenomena –multiphase flows, chemical reactions, heat, and mass transfer. To remain competitive in the market and consistently produce quality products with a higher yield, conversion, and purity, companies in the chemical industry are actively turning to a comprehensive digital twin to go beyond the limitations imposed by traditional rules of thumb, while reducing waste and pollutants.

This paper includes several illustrative examples of real-world industrial applications highlighting the role and value of simulation in meeting these objectives.