Applications 3D

The Process Of Creating The Perfect Waffle

A nationally leading manufacturer of frozen waffles has a unique but aged problem. How do they adjust existing raw potato waffle batter manufacturing line while in a flat mold, to match waffle stripe lines to the mold for each waffle inside the individual cartons. This had become an issue due to waffle batter overflow at different cavities, if they put too little batter in, it would result in an incomplete waffle, which could not be sold, and vice thrown in waste, costing $$$$. If they put too much batter, excess along the excess material could get stuck at the waffle line causing conveyor system to stop, resulting production loss and line downtime challenges for the facility that could save 2-3 manhours multiple occasions while high-speed 35M running down with the technology Center 55 scanner. The resulting scan data was processed into the software and generated a digital surface model advanced digital modelling program allowed us to create a digital section of the two halves of the mold. Two waffle halves were complete by using a software cloud process which could compare both top and bottom piece and determine the amount of batter overflowing and mapping this to the waffle line, creating material flow CFD results then analyzed in Ansys® Fluent to determine the actual volume of the excess material. Cavity Applications® was able to achieve creating the perfect waffle.