Case – Consumer goods manufacturing
Digital Twin technology reduces commissioning time
A global consumer goods manufacturer needed to modify an automated packaging line while minimizing production downtime and reducing commissioning risks.
By partnering with CREADIS to implement Digital Twin technology, the manufacturer was able to test and validate the system virtually before physical installation, saving 3–4 weeks of workshop time and identifying 28 software deviations before commissioning.
Changing a live line without stopping production
The manufacturer needed to modify the layout and functionality of an existing automated packaging machine used to handle boxed products on pallets.
Implementing these changes presented several challenges. Software errors and unexpected system behavior could lead to delays during physical commissioning, potentially disrupting production and increasing project costs.
The manufacturer therefore needed a way to validate the modified system and test new functionalities before installation, while minimizing risks and ensuring a smooth transition to production.
A Digital Twin built for virtual commissioning
CREADIS supported the manufacturer by developing a Digital Twin of the packaging system, enabling virtual testing and commissioning before changes were implemented on the physical equipment.
The project began with workshops to define the required level of detail for the virtual model, balancing technical accuracy with development costs.
CREADIS engineers then integrated 3D models, electrical specifications and process logic into a virtual environment connected to the actual control software. This allowed the team to test system functionality, validate communication signals and identify potential software deviations before physical commissioning.
Through virtual commissioning, the engineers were also able to develop and test new machine functionalities without interfering with ongoing production.
Faster commissioning and a model to reuse
The Digital Twin solution delivered measurable improvements in project execution and established a foundation for future automation projects.
By shifting testing and validation to an earlier project phase, the manufacturer reduced uncertainty during commissioning and gained greater confidence in the performance of its modified production system.
The project demonstrates how Digital Twin technology can help manufacturers minimize commissioning risks, accelerate project execution and create long-term value from their engineering investments.
Digital twins
A Digital Twin is a virtual copy of a production system. It combines 3D models, electrical data and process logic. It connects to the real control software, such as a virtual PLC, so engineers can test how the machine behaves before anything is built or changed on the shop floor.
Teams can then find software errors early, try out new functions and train operators without stopping production.
A global consumer goods manufacturer needed to modify an automated packaging line while minimizing production downtime and reducing commissioning risks.
Our simulation services embed system logic directly into a virtual environment, enabling powerful proof-of-concept validation and performance analysis – before anything is built.
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