Our simulation services embed system logic directly into a virtual environment, enabling powerful proof-of-concept validation and performance analysis – before anything is built.
In emulation, the logic of your system runs on a virtualized version of the actual controller – such as a PLC or IPC. This enables virtual commissioning and software testing in a safe, controlled environment before deploying to the physical system.
By using the real control logic in a virtual setup, emulation helps identify and resolve issues early, significantly reducing the time, cost, and risk associated with physical commissioning.
Podcast
Want to dive deeper into what a digital twin really is and how it can transform your operations?
Check out our podcast episode: “Why digital Twins are no longer optional” where we explore the definition, benefits, and challenges of this powerful technology.
What simulation enables
What emulation enables
Knowing when and how to integrate digital twins into your existing project processes can be challenging. That’s where we come in.
At DIS/CREADIS, our engineers bring hands-on experience from real-world projects where digital twins have been successfully implemented. Whether you’re just exploring the possibilities or ready to take the next step, we provide expert guidance to help you:
To enable emulation and software-in-the-loop testing, a robust virtual environment is essential.
At DIS/CREADIS, our digital twin specialists have deep expertise in setting up these environments to support seamless integration and testing.
We handle the full virtualization stack, including:
Custom programming is often essential to make a digital twin compatible with specific software standards and project requirements.
Our digital twin team has extensive experience in developing custom scripts and logic to ensure:
Whether you’re working with proprietary systems or open platforms, we ensure your digital twin is fully functional, responsive, and ready for integration.
Training & support
Implementing digital twin technology requires more than just tools – it demands the right knowledge and skills. At DIS/CREADIS, we offer comprehensive training and hands-on support to ensure your team is equipped to both create and use digital twins effectively.
What we offer:
Whether you’re just starting out or scaling up your digital twin capabilities, we’re here to guide you every step of the way.
Faster commisioning through digital twin technology
A leading global manufacturer in the consumer goods sector sought to accelerate the deployment of a new automated packaging line, responsible for handling boxed products on pallets. To minimize production downtime and ensure a rapid, trouble-free launch, the manufacturer adopted advanced Digital Twin technology to virtually commission the new system – identifying and resolving issues before physical installation.
In the fast-paced world of consumer goods, any delay in launching new production equipment can have a significant impact on market responsiveness and profitability. The manufacturer needed to modify the lay-out and functionality of an existing packaging machine, a process often fraught with risk due to unforeseen software deviations during traditional commissioning. To overcome these challenges, the company turned to digital twin technology – enabling virtual testing and optimization ahead of physical deployment.
1. Tailored scoping
Initial workshops were held in order to define the Level of Detail (LoD). Topics included the complexity of the vision systems, detail level of robot controllers and universal vs. native communication protocols. The goal was to create a solution where costs were kept down without compromising the validity of functionality tests.
2. Seamless data integration
Key production data, including 3D models, electrical specifications, and process logic, were consolidated to create a comprehensive virtual model of the packaging system.
Full rendering
3. Rigorous virtual modeling
The virtual system was connected to the actual control software, allowing for thorough testing of all func-tionalities and control modules in a risk-free environment.
4. Virtual I/O validation
A complete virtual I/O test was conducted to verify all signal paths and ensure seamless communication between software and hardware components.
5. Virtual commissioning
New features and process changes were tested and refined in the digital environment, with deviations swiftly identified, documented, and resolved – well before the system reached the factory floor.
Tool rendering
By leveraging Digital twin technology for virtual commissioning, the manufacturer achieved significant business benefits:
Accelerated launch: The project realized a 3 – 4 week reduction in workshop time, enabling faster time-to-market for new product lines.
Risk mitigation: 28 software deviations were detected and resolved pre-installation, minimizing the risk of costly delays during physical commissioning.
Innovation enablement: 5 new machine features were developed and validated virtually, supporting ongoing process innovation without disrupting live operations.
Long-term asset value: The Digital twin model now serves as a reusable asset for future upgrades, operator training, and pre-acceptance testing – ensuring continued return on investment throughout the equipment’s lifecycle.
Scalable best practices: The project established a standardized Digital twin toolbox, enabling more efficient and scalable deployment of future automation projects across the organization.
Through the adoption of digital twin technology for virtual commissioning, this global manufacturer dramatically reduced time-to-market, improved operational reliability, and created a foundation for ongoing innovation demonstrating the transformative commercial value of digitalization in modern manufacturing.
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