From feasibility study to digital optimization – a successful collaboration with Everllence

When Everllence, a leading German provider of propulsion, decarbonization, and efficiency solutions for shipping, the energy economy, and industry, sought to optimize their test program for multi-megawatt turbochargers for ship engines, they turned to R&D Test Systems. What began as a feasibility study has now evolved into a promising development project thanks to close collaboration, mutual trust, and a shared ambition to push boundaries.

Last year, R&D Test Systems conducted a feasibility study to challenge and improve Everllence’s existing testing methods. By applying a new digital approach and analyzing historic measurement data, the team was able to demonstrate a potential reduction in measurement time of 25 to 40%.

“We were quite optimistic going in, but the actual results exceeded our expectations,” says Dr. Uwe Jassmann, Digital Lead at R&D Test Systems. “It became clear early on that we could deliver real, measurable improvements to their testing process.”

A reduction of this scale has significant implications. It impacts not only operational costs but also capital efficiency. Fewer test hours mean faster development cycles and better use of test bench capacity. Just as importantly, large-scale testing consumes a considerable amount of energy. Cutting test time directly reduces CO₂ emissions, which makes a meaningful contribution to Everllence’s ESG efforts.

Everllence also points to the quality of the collaboration as a key success factor. “We had some hope for what a digital approach could do, but we were surprised by how big the potential turned out to be. We have never had a supplier who clarified the task and understood our needs so effectively, and then delivered such impressive results in such a short time,” says Rüdiger Rehm, Head of Engineering Turbocharger Measurement at Everllence.

More than just a report

Rather than delivering a traditional technical report, the team provided a video walkthrough of the software in action. “We wanted to make the results tangible. So instead of a long PDF, we recorded a screen capture with a voice-over that walks the engineers through how to use the tool,” says Dr. Jassmann. “We also handed over a short technical note for background, but the focus was on usability.”

Turning insights into a real solution

The results from the feasibility study paved the way for a continued collaboration. The next step is to validate the methods using a broader set of historical data and integrate the new optimization tool—the “Online Performance Map Approximator (OPA)”—into Everllence’s test bench control system. The team will also package the methods in a user-friendly graphical interface designed for daily use by Everllence’s test bench operators.

Stronger together

“This is what happens when two engineering teams are willing to question each other’s assumptions,” says Dr. Jassmann. “Everllence brought deep domain knowledge. We brought digital tools and new perspectives. Together, we’ve built something that neither side could’ve done alone.”