Process & Manufacturing Simulation Consultancy
Standards & Regulatory Context
DSEAR 2002
Controls risks from dangerous substances, fire and explosive atmospheres.
COMAH 2015
Addresses major accident hazards involving dangerous substances at higher-risk sites.
Pressure Systems Safety Regulations 2000
Covers the safe operation and integrity of relevant pressure systems.
Pressure Equipment Safety Regulations 2016
Sets safety requirements for pressure equipment such as vessels and pipework.
PUWER 1998
Sets requirements for the safe use and management of workplace equipment.
Frequently Asked Questions
Process & Manufacturing Projects
Discuss Your Process or Manufacturing Project
Tell us the engineering decision you need to make, the information you already have and the timescale you are working to. Your enquiry will be reviewed by a CFD engineer, who will acknowledge your enquiry within one working day and identify the most proportionate next step.
Mansim helps manufacturers, process operators, technology developers and engineering teams understand why industrial systems behave as they do, and how to improve them before committing to equipment changes, scale-up or capital investment.
We combine CFD, process modelling, multiphase simulation, heat and mass transfer, optimisation and experimental validation across reactors, mixing systems, dryers, furnaces, filtration technologies and complete process lines. Our simulations connect local equipment physics with plant-level performance to improve throughput, product consistency, energy efficiency, safety and scale-upconfidence.
Process & Manufacturing Engineering Challenges
Scaling Processes Without Losing Performance
Scale-up can change mixing, residence time, heat transfer and multiphase behaviour.
Increasing Throughput and Product Consistency
Poor mixing, uneven temperatures and non-uniform residence time can limit output and product quality.
Reducing Energy and Resource Consumption
Simulation can identify inefficient heat transfer, circulation and operating conditions that increase energy use.
Managing Process Risk Before Physical Modification
Alternative designs and operating scenarios can be tested virtually before changing production equipment.
Mansim Process & Manufacturing Capabilities
From Raw Material to Optimised Production
1. Feed & Materials
Characterise the flow, thermal and material behaviour entering the manufacturing process.
2. Mixing & Reaction
Assess circulation, mixing time, reaction environment, residence time and temperature uniformity.
3. Separation & Drying
Model multiphase transport, moisture removal, particle capture and separation performance.
4. Thermal Processing
Understand heat transfer, temperature distribution, energy consumption and high-temperature process behaviour.
5. Industrial Scale-Up
Determine how laboratory or pilot technologies will behave when transferred to industrial operation.
6. Optimisation & Assurance
Compare designs and operating strategies against production, energy, safety and commercial requirements.