Digital Twin Line Integrates Food Production Systems

Food manufacturers are increasingly adopting digital technologies to integrate processing and packaging into unified production environments. In this context, Rockwell Automation will present a fully virtual biscuit production line at Interpack 2026 (May 7–13, 2026, Düsseldorf, Germany), demonstrating how digital twin technology and connected data architectures can support end-to-end manufacturing operations.

A full production line recreated in a virtual environment
The demonstration covers the entire biscuit production lifecycle, including dough preparation, kneading, baking, cooling, primary and secondary packaging, and palletizing. This continuous process is modeled as a single, integrated system, reflecting how multiple production stages can operate within a shared digital framework.

The setup combines systems from multiple OEMs, including Royal Kaak for kneading, GEA for deposition, cooking, and cooling, Mespack for primary packaging, Vimco for secondary packaging, and Cetec Industrie for palletizing. These systems are integrated into a unified environment to represent a realistic multi-vendor production line.

Digital twins enabling parallel engineering workflows
The virtual production line is developed using Emulate3D™ digital twin software, which models real machines and production equipment. Rockwell technologies, including the iTRAK^® intelligent drive system, are incorporated to simulate motion control and system behavior.

By replacing physical equipment with virtual models, engineering tasks such as mechanical design, electrical integration, and automation configuration can be performed simultaneously. This approach enables earlier validation of system performance, reducing commissioning risks and improving alignment between engineering, operations, and maintenance teams before deployment.

Data architecture connecting machines and applications
The system relies on a connected data architecture that integrates machines and applications from different suppliers into a single operational layer. Technologies such as FactoryTalk Optix provide a shared data environment, allowing consistent data exchange across processing and packaging stages.

This unified data layer supports the implementation of digital twin models and enables monitoring of production performance, product quality, and traceability. It also reflects a shift toward a digital supply chain, where data continuity across systems is critical for operational visibility and coordination.

Cybersecurity and system-level integration
The architecture incorporates multi-layered cybersecurity through solutions such as the SecureOT™ platform, addressing the need to protect interconnected industrial systems. Open and scalable data structures allow different vendor systems to operate within the same environment while maintaining secure communication and control.

This approach enables collaboration between OEMs, system integrators, and end users, supporting the deployment of complex, multi-vendor production systems without requiring isolated control environments.

AI-supported operations across the production lifecycle
Artificial intelligence and machine learning functions are applied across the virtual production line to support stable and efficient operation. These technologies contribute to process monitoring and system optimization, ensuring that performance targets can be evaluated and adjusted across the entire production workflow.

Moving beyond isolated production assets
The virtualized production line demonstrates how manufacturers can transition from isolated equipment setups to integrated, data-driven production environments. By combining digital twins, connected data architectures, and multi-vendor system integration, the model provides a framework for designing and validating production systems before physical implementation.

This approach supports scalable deployment of food processing and packaging systems while improving coordination across the production value chain.

Edited by Aishwarya Mambet, Induportals Editor, with AI assistance.

www.rockwellautomation.com