Virtual Prototyping for Industry

The challenge

Industry is changing rapidly worldwide. Reliable energy supply is less obvious and more expensive, labour markets are tight, and the pressure to decarbonise and innovate keeps rising. At the same time, implementing new technology directly in live operations is risky: downtime, missed production targets or safety issues are real concerns.

Many companies are open to new technology to improve their processes – new equipment, better cooling concepts, or innovative fire protection solutions. But without a robust prediction of performance, it is difficult to justify investments and convince stakeholders.

Virtual prototyping for industrial processes

Bridging the gap

Virtual Prototyping bridges the gap between existing industrial assets and new technology. By testing, validating and optimising solutions in a digital twin first, you drastically reduce risk before physical implementation.

Our leaflet summarises how Virtual Prototyping works, the steps we take and the type of results you can expect.

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Our approach: Virtual Technology Prototyping

With Virtual Technology Prototyping, AMELA develops high-fidelity digital prototypes of your processes and installations. This allows you to test designs, validate performance and reduce development risk long before physical realisation.

We work in three clear steps to quantify what a technology delivers and how to implement it effectively:

1. Status Quo

We build a detailed picture of your current operations and processes. Technical data, process parameters and boundary conditions are captured so that the digital model accurately represents your reality.

2. Virtual Placement

New technology – for example a new system, PFAS-free foam or an upgraded cooling concept – is quantified and virtually placed in your existing environment. We define technical and financial constraints and explore multiple design variants.

3. Simulation & Scenarios

Through simulation we analyse how design and operational choices perform. We explore scenarios, sensitivities and “what-if” cases so you know exactly which combination of decisions yields the best outcome.

The result: better investment decisions, reduced failure costs, shorter development cycles and greater confidence in the performance of your future assets.

In practice

Virtual Prototyping already proves its value in real-world cases:

Case: Impala

Challenge

PFAS-free foam must be used in an existing fire-fighting system. The flow properties of the new foam are uncertain, and the impact on the installed system is unclear.

Approach

AMELA builds simulations that show how the new foam behaves in the piping, fittings and nozzles. Multiple configurations are compared and evaluated against relevant standards and requirements.

Result

Uncertainty is removed: the client knows exactly which technical and operational adjustments are required for safe and reliable implementation.

Case: Elbrons

Challenge

The client suffers from warm air intake at coolers, causing production targets to be missed. The question: what is the real benefit of upgrading the installation?

Approach

AMELA simulates flow profiles under different wind conditions and operating points. We identify the root causes of warm air intake and virtually evaluate several design options, calibrated with on-site measurement data.

Result

The client gains a clear view of which design choices deliver the best result. The selected solution can be implemented with confidence and predictable performance improvement.

Curious what Virtual Prototyping can do for your operation?

We are happy to discuss your specific situation. Together we explore how virtual prototypes can reduce investment risk, improve performance and accelerate innovation.