Digitalization of (bio-)processes

We transfer your processes to the digital world

At Fraunhofer IGB, we have been working for several years on projects to develop digital applications and integrate them into process engineering practice – also as a service provider for companies. We have extensive expertise in process technology and our know-how in modelling, simulation and data management. This enables us to provide companies with the best possible advice and support on the path to process digitalization and automation. You benefit from our many years of experience and expertise in automation technology, scaling, design and construction of process plants.

This enables us to support you along the entire development chain of a process – from research and development on a pilot plant scale to implementation in the technical, automated process with remote monitoring in real time.

Process digitization: opportunities and challenges

Digitalization in process engineering is creating the basis for far-reaching progress and new opportunities: Processes can be optimized through the intelligent networking of plants and systems via communicating sensor networks and the combined use of data analysis and digital twins. But that's not all: different process steps can also be seamlessly merged, integrated and automated.

However, in reality – from a digitalization perspective – many processes are still in the pilot phase. There are many reasons for this: the existing measurement technology and database are often separate data and isolated software solutions that cannot be integrated. In addition, communication between individual system modules is frequently still inadequate and important process data only displayed as a snapshot. Also, the introduction of digital and AI-based tools is time-consuming and requires process engineering expertise along the entire process chain in addition to IT skills for the implementation of system integration measures.

A large number of companies, especially SMEs, can hardly perform time-consuming and cost-intensive digitalization tasks due to limited capacities, a lack of skills and the simultaneity of various other challenges, meaning that the benefits that would result from process digitalization are still used far too rarely.

Our offer: We optimize your processes through digitalization

Our unique selling point

We combine process knowledge with digitalization. We understand your processes and digitize your data for the cost-efficient optimization of your process management. We achieve this with initial data analysis, efficient data communication and simulation-based control using digital twins.

Data structuring: We create the prerequisites for the application of AI in process technology

In order for analyzed process data to be used for the digital optimization and control of processes, it must first be made accessible to the respective users (process operators, planners, scientists).

To this end, we are creating an organized and process-oriented data structure at Fraunhofer IGB. This is a prerequisite for the use of any AI tools for data evaluation and modelling or simulation. Structuring the available data is therefore a fundamental milestone on the path to the digitalization of processes.

Data management: We ensure that your data communicate with each other and make it AI-enabled

Our main focus at Fraunhofer IGB is on integrated and process-oriented data management. To this end, we analyze your measurement data and ensure that all data is collected, integrated into the structure and can communicate with each other: The networking of a wide variety of data and protocol formats, automated transfer and backup of plant data (including offline data such as analytics data) create the prerequisites for smart process control and automation as well as efficient data processing (operational analysis, modelling etc.).

Our data management is cost-efficient, as it requires only a small amount of hardware and dispenses with expensive commercial solutions.

Our offer at a glance

Data management concepts
Creating a data structure for the central integration of online/offline data
Visualization of data and remote monitoring in real time
Development of innovative regulation/control concepts
Modeling and optimization of process engineering processes

Optimization and automation of your processes

We optimize operational management through remote monitoring in real time

Thanks to the efficient data structure, the process data can be used simultaneously for visualization, automation and modelling tasks. We use it to visualize the process, for process optimization through operational analysis and for the development of innovative automation concepts. We use this knowledge to implement system monitoring and system control for your process as remote monitoring in real time.

We select the necessary sensors and actuators in such a way that the right data is collected to control the system. We also develop soft sensors to save costs for complex measurement technology, such as flow sensors. With the right programming, these can calculate the required data from measuring points that have already been collected.

We also develop models, so-called digital twins, which we can use to program a simulation-supported control system in order to optimize your process. This makes it possible to vary process parameters dynamically, for example to minimize energy input or maximize product yield.

Plant planning: design and scenario evaluation through process simulation

We design your system with the required system components. To do this, we balance and model your processes using mass and energy balances. We rely on physical modelling methods, but also use AI tools or hybrid models if required. Using process simulations, we can predict the efficiency of your planned plant and thus increase the profitability of your project. Unpredictable parameters are often also crucial for the optimal operation of plants: different locations, seasons or weather conditions make it necessary to adjust the process control. This dynamic data can be incorporated into our calculations (MatLab/Simulink), enabling us to forecast models for various scenarios with our simulations.

Your advantages

Qualified advice for planning new systems
Flexible structuring of existing data (we make your process AI-capable)
Flexibilization of operations
Better understanding of processes
Increased system security through the use of online data
Faster response to error messages for proactive maintenance (predictive maintenance)
Minimization of downtimes
Reduction in personnel deployment
Cost reduction through savings in operation and maintenance
Improved process efficiency through adapted control strategies