Packtwin™: ai-powered digital twins for packaging optimization
PackTwin™ integrates AI with physics-based digital twins to optimize packaging design by simulating structural, barrier, usability, and manufacturability aspects. It reduces the need for physical prototypes and accelerates development cycles with high accuracy.
Overview
PackTwin™ is an advanced solution that leverages the power of AI and physics-based digital twins to revolutionize packaging design. By simulating structural, barrier, usability, and manufacturability aspects from a single 3D digital twin, PackTwin™ accelerates the packaging development process. This integrated approach reduces the dependency on physical prototypes, significantly cutting down on time and cost while maintaining high precision in predictions.
Technical specifications
PackTwin™ utilizes a combination of Finite Element Analysis (FEA) for top load and buckling, Computational Fluid Dynamics (CFD) for fill and squeeze simulations, and diffusion models for oxygen and water vapor transmission rates (OTR/WVTR). The system is enhanced with Bayesian optimized machine learning surrogates, such as Multi-Variate Gaussian Processes (MVGP) and Bayesian Optimization Gaussian Processes (BOGP), to deliver accurate predictions with minimal data. Key inputs include material properties, geometry, and logistics loads, while outputs cover top load, torque, seal integrity, and cost evaluations. A multi-objective Bayesian optimization engine swiftly recommends optimal changes to geometry, materials, and processes.
Technology readiness level
PackTwin™ is at TRL 6, indicating a mature technology that has been validated in relevant environments. The solution's efficacy has been demonstrated with less than 8% model error in pilot tests and significant optimization improvements, ready for further commercial application and scaling.
About Re-Du Company
RE-DU is a recycling technology company that has developed a patented process for the chemical deconstruction of mixed plastic waste. By breaking down diverse plastic types—such as PET, PC, PU, and PA—into monomers, the company enables the transformation of previously difficult-to-recycle materials into commercially valuable chemical products. This technology eliminates the need for costly sorting of mixed waste streams and offers an efficient, cost-effective alternative to traditional plastic management systems, which often rely on outdated processes that fail to address the majority of global plastic waste.
By providing a scalable solution for chemical recycling, RE-DU aims to reduce reliance on fossil fuels and minimize the environmental impact of plastic pollution in landfills. The company serves as a partner for industries seeking sustainable chemical feedstocks and is contributing to the development of a circular economy. Supported by initiatives like the Innovation Crossroads Award and research collaboration with Oak Ridge National Laboratory, RE-DU is positioned to help transition toward a net-zero carbon society by proving that mixed plastic waste can be successfully converted into high-quality, reusable resources.
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