These issues can be minimised by introducing a digital twin – a virtual representation of the manufacturing process, sensors, valves and actuators that reduces costs, improves reliability and optimises decision-making processes.
Developing, managing and adjusting hygienic processes can be fraught with delays and downtime to ensure the theoretical parameters are achieved consistently.
A digital twin offers a solution that can simulate the process before production starts. This enables fine-tuning to be done ahead of commissioning, reducing the time before production can start.
Simulating to save time
Digital simulations can also be run to see the effect of a change in parameters or review the best way to achieve a more efficient process. Using the digital twin, simulations can be used to optimise valve settings to the real conditions before any physical commissioning begins.
Furthermore, the link between the digital system and the physical one allow all the revised settings to be transferred seamlessly, saving time and resources. At the same time, cost efficiency can be maximised by lowering energy and material consumption.
Once the process is up and running, product quality is paramount in pharmaceutical as well as food and beverage production; any deviation from precise process parameters can result in rejected products and lost revenue.
Maintaining the precision of a process relies on sensor calibration and checks to verify accuracy.
The digital twin holds all the reference points for the process, monitoring numerous parameters and notifying the operator of any deviations.
Identifying the source of the issue at the earliest stage enables it to be corrected while the system continues to operate undisturbed.
By calibrating sensors virtually, using a laboratory reference, production continues without the need to remove the sensors.
Merging digital with reality
Real-time monitoring allows productivity to be maintained, ensuring all process parameters are within specification. Any deviations can be quickly identified and resolved, very often without the need for physical intervention. As with any high-value production process, saving downtime means maximising profitability.
In the longer term, the continuous synchronisation of physical and digital data enables operators to make proactive maintenance decisions, improving reliability and ensuring resources are used in the most efficient way.
In addition, when the manufacture of one product is coming to an end and a new process is required, the digital twin can be used to make test-runs before any changes need to be made.
After the simulation, optimised valve settings can be transferred to the actual production system, saving time, enabling the new product to be up and running with minimal delay. Bürkert’s digital twin solution offers many benefits from initial concept and throughout the production life cycle.
For more information about the digital twin and the benefits it offers, get in touch with our team at sales.uk@burkert.com to discuss your application today.