Client Overview
A major beverage bottling company in the Middle East sought to modernize its production operations by adopting digital twin technology. Their goal was to boost manufacturing efficiency, ensure quality, and optimize the entire bottling process—from raw material intake to final packaging.
Challenge
The plant faced recurring challenges such as unplanned downtime, inconsistent product quality, and lengthy changeover times between different bottle designs. Monitoring real-time equipment status and predicting maintenance needs were manual and error-prone, impacting overall productivity.
Solution: Digital Twin Implementation
We partnered with a global leader in digital solution provider to deploy a digital twin of the plant—an exact virtual replica of the bottling production line. The digital twin included:
- Real-time data feeds from sensors on key machines (fillers, cappers, labelers, conveyors).
- AI-driven analytics for predictive maintenance and process optimization.
- Simulation capabilities for new bottle designs and production scenarios before physical changes were made.
- Remote monitoring via a secure web dashboard available 24/7 to technical teams across locations.
Results
- Productivity increased by 25% as downtimes were predicted and prevented through timely maintenance interventions.
- Product quality consistency improved due to enhanced process control and simulation-based troubleshooting.
- Reduced time-to-market for new bottle types since digital simulation replaced time-consuming trial runs.
- Operators could remotely troubleshoot and monitor the line, fostering collaboration and faster issue resolution