Digital Twinning in Food Manufacturing

Digital twins are emerging as a major player in food manufacturing, offering a virtual representation of your production processes. Basically by  simulating and analysing real world operations, they provide actionable insights to improvements, for the purpose of this article we are going to take a look at planning and scheduling.   

Is Digital Twinning right for what we are trying to improve?

This depends on various factors which we can talk you through. As a guide if your operations are complex, with multiple variables that need to be balanced dynamically (perishable goods, multi site production), digital twins are ideal.   For smaller, simpler operations or businesses looking for faster, less expensive solutions, APS systems or AI driven tools might be a better option.

What is Digital Twinning?

A digital twin is a virtual representation of a physical object, process, or system that is continuously updated with real-time data. It’s essentially a living digital replica that mirrors and simulates physical operations, allowing businesses to analyse, predict, and optimise performance without disrupting actual operations.  The 3 key features you are going to benefit from are:

1. Digital twins are powered by real time data collected from sensors, machines, and other sources. This ensures they stay accurate and up to date.
2. They allow businesses to simulate scenarios, test changes, and predict outcomes without affecting the physical system.
3. Digital twins provide a dynamic connection between the physical and digital worlds, enabling constant improvements.  As ever the, Garbage in/garbage out rule holds firm.  Feeding unreliable data into a digital twin will yield unreliable results.

Insights gained from the digital twin inform decisions and drive improvements in the physical system.

What size of manufacturing operation can use digital twinning?

Though its adoption and implementation can differ based on scale, resources, and specific needs, regardless of operational size, the adoption of digital twins is becoming more feasible due to;

• Cloud based platforms  which lower costs and simplify integration. 
• Internet of Things (IoT) advancements have lowered the cost of  devices and sensors which make it easier to collect the data needed for digital twins.
• Subscription based models are reducing the financial barrier to entry.

At Chasm, we believe in being real and relevant and that means we will ensure that any digital twin technology used matches the scale and complexity of your operations.   For large operations, we can help implement fully integrated systems that span multiple sites. For smaller businesses, we focus on modular, cost effective solutions that deliver immediate value.

Large manufacturing operations and digital twinning

Large manufacturers often have the resources to fully integrate digital twin technology into their existing systems, such as ERP and and MES.   Key advantages include:

Digital twins can model complex, multi-site operations, helping large manufacturers coordinate across facilities and geographies.

They can incorporate sophisticated predictive analytics, real time monitoring, and AI driven insights.

Larger budgets often allow for highly tailored implementations, ensuring the technology meets specific business needs.

Small and medium sized manufacturing operations

Smaller operations might not require the same level of complexity, but they can still benefit significantly from digital twins for specific purposes, such as optimising a single production line or improving inventory management. 

Many software providers Chasm work with now offer modular digital twin solutions designed for smaller budgets.  

Chasm also bring the expertise needed to set up and maintain and interpret the digital twinnig system.  Most smaller operations do not have this expertise in house.

Simulating scenarios in planning and scheduling

At Chasm we believe that planning and scheduling is the centre of the operations universe.  Digital twins offer unparalleled precision to planning and scheduling and with the right human expertise ensure plans are executable. The simulation connects the physical and digital worlds, ensuring data flows seamlessly between your ERP, scheduling systems, and shop floor equipment.

Digital twinning allows you to model your manufacturing environment and test various scenarios in your planning and scheduling without disrupting actual operations. 

Here are 10 of our favourite scenarios:

1. Simulate production increases to understand bottlenecks and resource needs.
2. Use predictive analytics to anticipate disruptions and reallocate resources before problems arise.
3. Analyse the impact of different production schedules on efficiency, downtime, and labour costs.
4. Adjust schedules in real time based on unexpected changes, such as equipment failure or ingredient shortages.
5. By visualising workflows and identifying inefficiencies, digital twins help minimize waste and reduce production downtime:
6. Optimise batch production by simulating how to align product mixes with demand.
7. Ensure raw materials are used efficiently to meet shelf-life requirements.
8. Simulate the impact of increased demand on capacity and resources.
9. Improve inventory management by predicting stock levels and reducing waste.
10. Enhance quality control by identifying potential risks and inconsistencies in processes.

A bonus benefit is that digital twins create a shared virtual environment that all stakeholders can access. This transparency fosters better communication between production teams, planners, and supply chain managers, aligning everyone toward common goals. Communiation can be tricky in manufacturing where there are many opportunities for conflicting objectives to cause more than their fair share of problems.

Speak to us at Cham if digital twinning is something you want to investigate further.  Alternatively if you are interested in improving  your factory operations please reach out for an initial,  no obligation conversation with our MD Martyn King .