The Centre in Advanced Fluid Engineering for Digital Manufacturing (CAFE4DM)

Lead Research Organisation: University of Manchester
Department Name: Chem Eng and Analytical Science

Abstract

This 5 year project aims to address the challenges in understanding, creating and scaling up manufacturing processes for formulated products with particular reference to those in fast moving consumer goods (home/personal care and food products). The main objective is to develop a new modelling approach which will be combined with experimental measurements of the liquid properties to describe these complex fluids and enable a significant reduction in the conventional physical experimentation required to develop new formulations. The methodologies developed will provide a detailed understanding of the behaviour of these liquids under process conditions which will facilitate the decision making process and accelerate the introduction of new, innovative products to the market optimised to deliver benefits to consumers, e.g. shiny hair or mouthfeel for ice cream. The project brings together a multi-disciplinary team from the University of Manchester, the University of Cambridge and Unilever who are a global leader in the research, process design and manufacture of formulated products. The project is also supported by Process Systems Enterprise Ltd.. A major outcome of the project will be a demonstrator of the Industry 4.0 concept which will enable smart factories to be realised in the process sector and thus allow the UK to remain at the forefront of manufacturing in this field.

Planned Impact

The main areas of impact for CAFE4DM are in the following:

Society and Environment through a contribution towards environmental sustainability through reduced waste and increased energy efficiency.
Economic through increases in R&D productivity and factory capacity.
People through the delivery and training of highly skilled researchers and the retraining of the existing workforce within the project partners, in particular Unilever.
Outreach and Engagement by contributing to disseminating the methodologies developed to other formulated product industries and to contribute to increased public awareness and understanding of science, engineering, economic and societal issues.

This impact will be realised through dissemination activities to a wide range of stakeholders (industry, government, academics, general public). CAFE4DM will promote an understanding of the environmental and energy benefits of the implementation of Industry 4.0 within the process sector through outreach events for both the public and industrialists. In addition, the economic impact of this change will be realised through the development of an exploitation plan in consultation with the external advisory board and dissemination of the methods developed to a wider industrial, regulatory and academic audience through stakeholder meetings, workshops and conferences. The development of the next generation of scientists, engineers and managers will be achieved through training and the strong interactions within the project between industry, academia and ISIS. All the researchers will have exposure to these areas providing them with a versatile skill set which will benefit society and the UK economic prosperity through the knowledge economy. This pipeline of talent will ensure that the strong relationship between the partners allows the development of the methodology to higher TRLs and will enable the UK to remain a leader in the rapid development of products into the market place. Regular outreach activities will enable CAFE4DM to have a strong impact on the relevant stakeholders and also develop the communication skills of the researchers within the project. The impact activities will be managed by an academic with CAFE4DM with time allocated within the project specifically for this task. In addition, the RAs and PhDs within the project will spend 5% of their time on the organisation and delivery of outreach events. The impact workpackage leader will be on the management group of the project to ensure that the impact delivery plan is achieved and remains aligned to the core research activities.

Publications

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Panoukidou M (2019) Constructing the phase diagram of sodium laurylethoxysulfate using dissipative particle dynamics. in Journal of colloid and interface science

 
Description PSE 
Organisation Process Systems Enterprise Limited (PSE)
Country United Kingdom 
Sector Private 
PI Contribution NA - too early
Collaborator Contribution PSE has provided us with 5 gPROMS licences which will provides us with a suitable solver for different mathematical models and allows certain optimisation to be done.
Impact NA - too early
Start Year 2017
 
Description STFC 
Organisation Science and Technologies Facilities Council (STFC)
Country United Kingdom 
Sector Academic/University 
PI Contribution Industrial systems to examine and correlation of structure with phyisico-chemical properties and modelling studies.
Collaborator Contribution Access to ISIS beamline, modelling and synthetic expertise.
Impact No outputs to date. This is multidisciplinary research involving maths, physics, chemistry, mechanical engineering and chemical engineering
Start Year 2017
 
Description Unilever 
Organisation Unilever
Country United Kingdom 
Sector Private 
PI Contribution Technology transfer - ideas about how we will determine the structure of the complex fluids and model that structure.
Collaborator Contribution Technology transfer - which are the important parameters we need to look at, the components of these mixtures and concentration. They have also provided some materials.
Impact NA - too early
Start Year 2006
 
Description University of Cambridge 
Organisation University of Cambridge
Country United Kingdom 
Sector Academic/University 
PI Contribution Experimental validation of the modelling and simulation undertaken and incorporation of the models into a broader modelling framework.
Collaborator Contribution Equations of state with which to link the molecular scale modelling to the longer scale modelling to enable the prediction of properties for new formulation products.
Impact No outputs as yet. This is a multi-disciplinary collaboration involving maths, chemistry, physics, mechanical engineering and chemical engineering
Start Year 2017
 
Description University of Liverpool - MIF 
Organisation University of Liverpool
Country United Kingdom 
Sector Academic/University 
PI Contribution Provided the samples for experiments at the Materials Innovation Factory
Collaborator Contribution Provided use of HTR, FTIR and NIR at Materials Innovation Factory
Impact No outputs as yet. This is a multi-disciplinary collaboration involving maths, chemistry, physics, mechanical engineering and chemical engineering.
Start Year 2018
 
Description University of Manchester 
Organisation University of Manchester
Country United Kingdom 
Sector Academic/University 
PI Contribution We have increased the University's strategic partnership with Unilever via the Prosperity grant and this will lead to ongoing projects across the University.
Collaborator Contribution The University of Manchester provides 50% of the funding for our Project Manager. The University of Manchester is committed to provide funding (fees and stipend) for eight of the project's seventeen studentships; five of which have now started. The University has also provided half of the funding needed to purchase an NMR probe which is currently being installed.
Impact NA - too early
Start Year 2017
 
Description 12th International ERCOFTAC Symposium on Engineering Turbulence Modelling and Measurements 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Vipin Michael delivered a presentation at 12th International ERCOFTAC Symposium on Engineering Turbulence Modelling and Measurements, 26-28/9/18, Mountpellier, France
Year(s) Of Engagement Activity 2018
URL http://www.ercoftac.org/events/new_etmm12
 
Description British Science Week 2018 outreach event 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Schools
Results and Impact The University of Manchester held an open event across 13th - 16th March 2018 in association with British Science Week to allow local Schoolchildren to visit and be encouraged to engage and study the STEM subjects. CAFE4DM worked with the School of Chemical Engineering and Analytical Science during this event and provided support/time through the involved of CAFE4DM PDRAs. The experiment focused upon "Ooblek", a non-Newtonian fluid which is directly linked to the CAFE4DM project. No known impacts are known but we would hope it has sparked an interest in related subject areas.
Year(s) Of Engagement Activity 2018
URL https://www.britishscienceweek.org/
 
Description CCP5 (Computational Collaboration Project No.5) 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Charlie Wand presented a poster at computational chemistry conference, It sparked conversation and discussion.
Year(s) Of Engagement Activity 2018
URL https://www.ccp5.ac.uk/
 
Description Chao Li R&D Management Conference 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact The paper presented by Chao Li on "The Adoption of Digitalisation in R&D: Organisation & Behavioural Issues" was presented at the conference to an international audience. The presentation was followed by an intensive discussion on the topic and continued conversation with researchers in a similar field. Constructive feedback and insights were obtained at the conference.
Year(s) Of Engagement Activity 2018
URL http://www.rnd2018.polimi.it
 
Description Chao Li/WP4 attendance at "Internet of Things for Industry" event, 7/6/18, Cambridge 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact The workshop provided insights from various participants from different backgrounds, incl. what is IIoT, why IIoT, what are the implications and barriers? The workshop revealed the urgent demand but lack of systemic understanding and limited knowledge on industrial application of IIoTs and digitalization in firms.
Year(s) Of Engagement Activity 2018
URL http://www.ifm.eng.cam.ac.uk/events/iiot-june/
 
Description Charlie Wand attends Edward's Symposium 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Charlie Wand presented a poster and elevator pitch at the symposium. This generated discussion between participants from both an industrial and academic background.
Year(s) Of Engagement Activity 2018
URL https://www.turing-gateway.cam.ac.uk/event/tgmw56
 
Description Community Festival June 2018 - outreach event 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Public/other audiences
Results and Impact The University of Manchester held an open day event on 16th June 2018 with the aim of engaging local communities across Manchester with the work and research taking place at the University. CAFE4DM participated at this event which involved almost 2000 members of the general public in mostly family groups (over 80%). CAFE4DM ran a table-top interactive experiment focusing on "Ooblek", a non-Newtonian fluid which is directly linked to the CAFE4DM project. No direct impacts are known but we would hope it has sparked an interest from children into related subject areas.
Year(s) Of Engagement Activity 2018
URL http://www.socialresponsibility.manchester.ac.uk/strategic-priorities/engaging-our-communities/publi...
 
Description ISIS Large scale structures user meeting 2018 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact The ISIS Large scale structures (LSS) user meeting 2018 was a gathering of around 150 academics, postdocs, postgraduate students, and members of industry who are users of the large scale structures group instruments at ISIS. Presentations from users were given over 2 days along with updates from LSS staff. Discussions of the CAFE4DM project with other members of the meeting were had during breaks and evenings of the meeting.
Year(s) Of Engagement Activity 2018
URL https://www.isis.stfc.ac.uk/Pages/ISIS-Large-Scale-Structures-User-Meeting.aspx
 
Description Philip Martin attending ACEForm 4.0 workshop 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Philip Martin attending the meeting AceForm 4.0: Positioning Formulation in future EU Framework Programmes hosted by Centre for Process Innovation, 14/3/18. This was a workshop with ~30 participants but the results are to be circulated to an EU audience of between 100 - 500. No impacts from this activity are known yet but it is part of a report in to the Formulated products industry EU wide with a road map for digitisation. The importance of lobbying for the next H2020 calls was emphasised.
Year(s) Of Engagement Activity 2018
URL https://www.uk-cpi.com/events/aceform-4-0-workshop
 
Description Philip Martin presenting at Industry 4.0 summit 2018 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Philip Martin attended Industry 4.0 summit, 28th February - 1st March 2018 and contributed a talk. The talk received some good feedback and invites to give further talks.
Year(s) Of Engagement Activity 2018
URL https://www.industry40summit.com/
 
Description RSc Formulation 4.0 Meeting 13th Dec 2018 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Professor Philip Martin (UoM) and Dr Jo Cook (Unilever) delivered a joint invited presentation about how the CAFE4DM project is pioneering the development and application of digital manufacturing techniques in formulated products from both the academic and industrial side. As a result of this activity a possible new collaboration for the future is in discussion.
Year(s) Of Engagement Activity 2018
URL http://www.rsc.org/events/detail/36096/formulation-4-0
 
Description Research Student Event of the Fluid Mixing Processes Special Interest Group of the IChemE 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact The annual Research Student Event of the Fluid Mixing Processes Special Interest Group of the IChemE, FMP-SIG was hosted by Dr Thomas Rodgers at University of Manchester, sponsored and supported by the CAFE4DM project. This annual event aims to bring together UK based research students to present their findings in the field of fluid mixing processes to their peers and professionals from industry and academia.

The winning PGR student with the best presentation has received a special presentation slot at Mixing16 (September 2018) to present their work - this is one of the leading international conferences in the field.
Year(s) Of Engagement Activity 2018
URL http://www.icheme.org/communities/special-interest-groups/fluid%20mixing%20processes/events/2018/res...
 
Description Science X 2018 - outreach event 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Public/other audiences
Results and Impact The University of Manchester held an outreach event called "Science X" at the Trafford Centre, Manchester on 14th & 15th April 2018. The purpose of the event is for the general public to experience what it is like to work in Science at the University and consequently encourage engagement with STEM subjects. CAFE4DM and the School of CEAS jointly held a stand at the event on 15th April 2018 with an experiment focusing upon "Ooblek", a non-Newtonian fluid and non-Newtonian fluids are very relevant to the CAFE4DM project. No known impacts are known but we would hope it has sparked an interest in related subject areas. Around 600-700 children of varying ages attended the stand over the course of the day along with their parents.
Year(s) Of Engagement Activity 2018
 
Description UoM Science Spectacular 2019 outreach event 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Public/other audiences
Results and Impact The University of Manchester held "Science Spectacular" on 20th Oct 2018, an annual family science fun day which is part of the Manchester Science Festival. CAFE4DM participated at this event which involved over 1000 members of the general public. CAFE4DM ran a table-top interactive experiment focusing on "Ooblek" which is a non-Newtonian fluid and a visual table-top experiment focusing on "Boger fluid" which is an elastic fluid with constant viscosity. No direct impacts are known but we would hope it has sparked an interest from children into STEM subjects.
Year(s) Of Engagement Activity 2018
URL http://www.manchestersciencefestival.com
 
Description gPROMS training by PSE 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Professional Practitioners
Results and Impact As part of their in-kind commitment the CAFE4DM project hosted a gPROMS training event with Process Systems Enterprise (PSE) visiting the University of Manchester and delivering a training over two days. Members of the project attended the training but also other staff and students not directly associated with CAFE4DM. It has been expressed that having the training in the software has provided attendees with insight into its capabilities which will be beneficial for future projects.
Year(s) Of Engagement Activity 2018