Liquid Spray Coating Using Discrete Droplet Model​ (ABP)

This Application Best Practice (ABP) provides a step-by-step guide for simulating liquid spray coating processes using the Discrete Droplet Model within Ansys Rocky™ particle dynamics simulation software. It introduces the industrial relevance of spray coating in pharmaceutical and food sectors, outlines common challenges such as coating uniformity and spray waste, and demonstrates how simulation can optimize performance and reduce physical testing. The methodology leverages the DEM Liquid Spray module to replicate realistic spray behavior, configure nozzle surfaces and regions of interest (ROIs), and analyze coating outcomes. Through detailed setup instructions and result interpretation, users gain practical insights into achieving efficient and uniform coating with minimal waste. 

Learning Outcomes:

Following completion of this Application Best Practice (ABP), you will be able to: 

• Understand the fundamentals and industrial applications of liquid spray coating, particularly in pharmaceutical and food industries, including its benefits such as improved product quality, protection, and shelf life. 
• Identify and analyze common challenges in spray coating processes, such as coating uniformity, quality control, overspray, and environmental factors, and understand how simulations can help mitigate these issues. 
• Apply the Discrete Element Method (DEM) Liquid Spray module in Ansys Rocky software to simulate spray behavior, configure nozzle surfaces and ROIs, and interpret simulation outputs like coating uniformity and spray waste. 
• Configure simulation parameters and geometry accurately, including spray nozzle setup, particle properties, and advanced solver settings, to replicate realistic spray patterns and optimize performance. 
• Evaluate simulation results using metrics such as Coefficient of Variation (CoV) to assess coating uniformity and estimate process duration, while comparing outcomes against reference tutorials and minimizing physical testing. 

Prerequisites:

• Chapter 1: Tutorial - Transfer Chute   

• Chapter 9: Tutorial – Tablet Coater  

• Chapter 16: DEM Liquid Spray 

Please note: These training materials were developed and tested in the 2025R2 release.

Application Best Practices (ABPs) outline engineering design goals for specific applications and provide guidance for how to achieve those goals using Ansys simulation software. It is important to note that a Geometry File or other Input Files are not always available. ABPs, as opposed to the official training-material workshops/tutorials, are not meant to be a step-by-step instruction document. ABPs are a link between product-based training courses and application specific tutorials, educating on the "how" and "why" of the best modeling approach, highlighting best practices and workflows for a particular application.