Energy-efficient start-up optimization via digital twin for a vegetable broth sterilization process

IF 5.8 2区农林科学 Q1 ENGINEERING, CHEMICAL

Journal of Food Engineering Pub Date : 2025-09-30 DOI:10.1016/j.jfoodeng.2025.112822

Marcello Maria Bozzini , Marco Menegon , Alberto di Loreto , Gaia Lunari , Silvia Serena Mariani , Mattia Vallerio , Laura Piazza , Flavio Manenti

{"title":"Energy-efficient start-up optimization via digital twin for a vegetable broth sterilization process","authors":"Marcello Maria Bozzini , Marco Menegon , Alberto di Loreto , Gaia Lunari , Silvia Serena Mariani , Mattia Vallerio , Laura Piazza , Flavio Manenti","doi":"10.1016/j.jfoodeng.2025.112822","DOIUrl":null,"url":null,"abstract":"<div><div>The food industry is undergoing a digital transformation driven by the need for greater sustainability, efficiency, and data integration. This study presents a methodology for implementing a digital twin in an industrial food manufacturing process, using the vegetable broth production line as a case study. The workflow integrates process analysis, sensor data collection, and data reconciliation to improve the reliability of process variables and enable accurate simulation. The reconciled data were used to develop a dynamic model in commercial software, capable of simulating different operating conditions. Two start-up strategies, cold start-up and pre-heating, were compared, revealing that pre-heating reduces steam consumption by 62% and start-up time by 63%. These results demonstrate the potential of digital twins in optimizing operational efficiency and energy use in the food industry. Future developments may include real-time data acquisition, integration with control systems, and the use of AI for predictive maintenance and process optimization.</div></div>","PeriodicalId":359,"journal":{"name":"Journal of Food Engineering","volume":"406 ","pages":"Article 112822"},"PeriodicalIF":5.8000,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Food Engineering","FirstCategoryId":"97","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0260877425003577","RegionNum":2,"RegionCategory":"农林科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"ENGINEERING, CHEMICAL","Score":null,"Total":0}

引用次数: 0

Abstract

The food industry is undergoing a digital transformation driven by the need for greater sustainability, efficiency, and data integration. This study presents a methodology for implementing a digital twin in an industrial food manufacturing process, using the vegetable broth production line as a case study. The workflow integrates process analysis, sensor data collection, and data reconciliation to improve the reliability of process variables and enable accurate simulation. The reconciled data were used to develop a dynamic model in commercial software, capable of simulating different operating conditions. Two start-up strategies, cold start-up and pre-heating, were compared, revealing that pre-heating reduces steam consumption by 62% and start-up time by 63%. These results demonstrate the potential of digital twins in optimizing operational efficiency and energy use in the food industry. Future developments may include real-time data acquisition, integration with control systems, and the use of AI for predictive maintenance and process optimization.

查看原文本刊更多论文

基于数字孪生的蔬菜肉汤灭菌过程节能启动优化

由于需要更大的可持续性、效率和数据集成，食品行业正在经历一场数字化转型。本研究提出了一种在工业食品制造过程中实施数字孪生的方法，使用蔬菜肉汤生产线作为案例研究。该工作流集成了过程分析、传感器数据收集和数据协调，以提高过程变量的可靠性并实现准确的仿真。利用协调后的数据在商业软件中建立了一个动态模型，能够模拟不同的操作条件。通过对冷启动和预热两种启动策略的比较，发现预热可以减少62%的蒸汽消耗和63%的启动时间。这些结果证明了数字孪生在优化食品行业的运营效率和能源使用方面的潜力。未来的发展可能包括实时数据采集，与控制系统的集成，以及使用人工智能进行预测性维护和过程优化。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

求助全文

约1分钟内获得全文求助全文

来源期刊

Journal of Food Engineering 工程技术-工程：化工

CiteScore

11.80

自引率

5.50%

发文量

275

审稿时长

24 days

期刊介绍： The journal publishes original research and review papers on any subject at the interface between food and engineering, particularly those of relevance to industry, including: Engineering properties of foods, food physics and physical chemistry; processing, measurement, control, packaging, storage and distribution; engineering aspects of the design and production of novel foods and of food service and catering; design and operation of food processes, plant and equipment; economics of food engineering, including the economics of alternative processes. Accounts of food engineering achievements are of particular value.