Combined modelling methodology for optimisation of box design based on hybrid genetic algorithm

Abstract

The hybrid genetic algorithm (HGA) was used to optimise box design to maximise cooling performance, mechanical performance, pallet footprint, and container packing efficiency and to minimise cardboard usage. These factors are normally investigated independently, but the industry requires combined functionality. Here, we present a case study, for optimisation of regular slotted carton boxes filled with wrapped beef mince. After packing, individual boxes are chilled to a desired storage temperature and then palletised for shipping. Four models were developed to predict design performance, including cooling rate, mechanical performance, cardboard usage, and box stacking on pallets. The combination of the model results was used to score the average performance of box designs. The models were solved by Comsol Multiphysics, Ansys APDL, and Cape Pack. The overall design generation and optimisation were developed with Matlab that controls all these software packages, evaluates the interactions between results, and runs the HGA for box optimisation. The HGA was conducted for 10 generations each with a population of 100 individuals. The optimisation routine successfully found optimum dimensions for the box for the defined conditions with relative short simulation times (about 3 hours per generation). This paper demonstrates how overall optimisation of packaging can be achieved through combining the strengths of multiple simulation software packages.

Crushing of Double-Walled Corrugated Board and Its Influence on the Load Capacity of Various Boxes

“…The laminate shell stiffnesses were computed for three crushing levels of corrugated cardboard, in which the crushing levels were 10%, 20% and 30%, but also for the intact cardboard (0% of crushing). Selected values of the stiffnesses computed, required to estimate the compressive stiffnesses of the packaging according to Equation (19), are presented in Table 6. Also, the values of ECT computed according to Equation (23) for different levels of crushing are presented in the same table in the last row.…”

“…The main aim of the numerical part of the study was to check what is the influence of the particular level of crushing for double wall corrugated cardboard packaging on its compressive strength. Therefore, varied dimensions of large corrugated cardboard boxes were selected and computed according to the analytical approach presented in Equation (19). Typical flap boxes were analyzed.…”

“…Bookmark not defined.] or with more heuristic approach to design [19,20]. Currently, the practitioners know that crushed material is weaker, but does not have the techniques/tools/models to measure how much and which technological process is the most crucial here.…”

Crushing of Double-Walled Corrugated Board and Its Influence on the Load Capacity of Various Boxes

“…From an industry 4.0 point of view, more information on the crushing of cardboard material during production due to different technological processes would enhance quality control significantly. Optimal solutions and savings for box designs are available due to advanced mathematical modelling; this may be related to a single-box feature [1,3] or to a more heuristic approach to design [27,28]. Currently, practitioners know that crushed material is weaker, but they do not have the techniques, tools or models to measure how much or which technological process is the most crucial here.…”