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Molded fiber production runs on three linked stages, forming, dewatering, and drying, and a weakness in one shows up as cost in the next. Generic fixes rarely hold because the real constraint is specific to your fiber, your recipe, and your equipment, and it's easy to guess wrong from the outside.
CFDτϵχ starts on your factory floor, not behind a screen. We bring metrology and physics-based understanding to your line, identify the actual root cause with your data, and only then engineer a solution, so the fix targets what's really limiting throughput, consumption, or consistency, not what a generic model assumes it should be.
Every engagement follows the same rigorous methodology, but the scope is built around what you actually need, sized to your requirements and your budget.
Drying Performance
Drying Performance
Drying is where the gas bill actually gets written, and with little in-process moisture measurement, most lines run it on habit rather than real numbers, so margin swings with every move in the energy market.
CFDτϵχ standardizes drying performance across your lines, so every one runs to the same target instead of drifting on operator feel, for more throughput and less gas burned per part, without adding a single kilowatt of heat.
Heat & Mass Balance
In-oven profiling
Ring-to-ring analysis
Level-to-level analysis
Efficiency quantification
Process optimization
Flow distribution
Blowing efficiency
Heat recovery
Calibrated model of your oven
Exploration of best configurations
Throughput, consumption, ROI
Mitigation solutions
Coordination w/ E&C
On-site validation
Measured energy gains
Final assessment
Dewatering Performance
Dewatering Performance
Removing water by mechanical action with vacuum is far more efficient than by evaporation: a 1% gain in dryness converts into a 3.5% saving in drying energy. The levers to get there exist, but none of them are universal, the right fix depends on your fiber, your recipe, and your machine.
CFDτϵχ brings state-of-the-art physics understanding together with factory and lab data and modeling, to quantify what an investment, a new pump, a recipe change, is actually worth before you make it.
Vacuum system characterization
Pressure/temperature measurement
Vacuum dynamics
Other factors (consistency, recipe)
Lab fiber hydraulic characterization
Effect of temperature
Effect of vapor addition
Virtual pump change
Coordination w/ E&C
On-site validation
Measured dewatering gains
Final assessment
Forming Performance
Forming Performance
Consistent and uniform production is the baseline for performance. A heavier product limits line throughput; a lighter one risks part strength. Variation shows up at different scales, a spot on the product, a ring of the machine, or a drift over time.
CFDτϵχ quantifies and analyzes the root cause of these variations before you engineer a fix.
We also support tooling design, in particular the integration of new technologies such as 3D printing, which has moved from experimental to proven over the last five years.
Vacuum pressure
Ring-to-ring variability
Time variability
Consistency distribution
Actual slurry velocity
Effect of temperature
Slurry flow in forming tank
Effect of slurry level
Effect of slurry flow rate
Ring-to-ring balancing
Steady product weight
Coordination w/ E&C
On-site validation
Measured forming improvements
Final assessment
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