DIGITAL TWINS


FUNCTIONAL INGREDIENTS Rockwell Automation showcases the Emulate3D Factory Test digital twin solution


for virtual controls testing at Hannover Messe 2025. (Image: © Rockwell Automation press)


packaging also benefit from predictive modelling. Factors such as cooling tunnel speed, tempering temperatures, and filling pressures can be simulated in a virtual environment, allowing manufacturers to identify optimal configurations before touching the physical line. Tetra Pak has taken a similar approach with its packaging equipment, modelling liquid flow, mechanical stresses, and film behaviour to anticipate issues and reduce material waste. “As you can imagine, our machines operate extremely fast, and even minor errors in packaging formation can cause significant waste,” says a Tetra Pak process engineer. “By simulating these conditions digitally, we can anticipate issues before they occur in the plant.”


Accelerating simulation and optimisation through AI-driven twins Another compelling example from late 2025 comes from Krones, a leading global provider of processing, filling and packaging technology for food and beverage manufacturers. In December 2025, the company announced a new generation of AI-enabled digital twins that harness advanced simulation and machine learning to dramatically accelerate production modelling. Although Krones often supplies beverage lines, the principles of flow, temperature control, filling accuracy and packaging speed directly map to confectionery processes such as chocolate bar enrobing, sugar panning, and gummy dosing systems. Krones’ system uses physics-based simulations and continuous optimisation loops to support real-time decision-making. What was previously a labour-intensive simulation process taking hours has


30 • KENNEDY’S CONFECTION • MARCH 2026


been reduced to under five minutes, enabling engineers to test multiple scenarios and automatically optimise key parameters such as speed, temperature and control logic. For confectionery lines, this translates into faster validation of production adjustments without risking tempering errors in chocolate, inconsistent gelatin setting in gummies, or uneven fillings in pralines. “We are demonstrating that


digitalisation and AI are not just visions for the future but deliver tangible efficiency gains and sustainable benefits today,” said Markus Tischer, Member of the Executive Board of Krones. The same benefits — reduced downtime, improved yield, and faster scenario testing — can help confectionery manufacturers respond quickly to seasonal peaks or new product launches, where precision and speed are critical.


Faster line deployment In early 2026, Rockwell Automation highlighted how digital twin technology is accelerating project delivery and enhancing operational performance for industrial automation customers. In a press release detailing a deployment with Falcare Industrial Equipment in Brazil, Rockwell explained how its Emulate3D™ digital twin platform was used to simulate mechanical behaviour — from conveyor speeds to robot motion — long before physical systems were installed. This virtual commissioning approach enabled the customer to complete projects 60 % faster by identifying issues and validating control logic in a digital environment rather than on the factory floor. The result was improved precision and quality, reduced waste and energy use, and more confident decision-making ahead of implementation. For confectionery manufacturers,


these benefits are directly applicable. Production lines for chocolates, candies, gummies and baked treats rely on a tightly coordinated interplay of conveyors,


dosing systems,


thermal processes and automated wrapping stations — all of which must operate at high throughput and with minimal variation. By using digital twin simulation to test these systems virtually, confectionery engineers can reduce commissioning time, avoid costly physical rework and prevent product loss due to mis-tuned equipment. Rockwell has also been advancing


DIGITAL TWINS LET US EXPLORE RECIPE


ADJUSTMENTS THAT MIGHT


TAKE WEEKS OR MONTHS TO TRIAL PHYSICALLY,” – ELENA ROJAS, BLENDHUB.


digital twin capabilities for full-factory simulation. At Hannover Messe 2025, the company launched Emulate3D Factory Test™, designed to support factory-scale virtual controls testing by combining mechanical, electrical, process and robotics behaviour into a unified digital twin before a single component is installed. According to Rockwell, this approach enables virtual Factory Acceptance Testing (FAT) and provides teams with an unprecedented view of how automation systems will behave in complex environments. “Scaling digital twins to the full factory


level is critical for modern industrial operations,” said Matheus Bulho, senior vice president of software and control at Rockwell Automation, upon the technology’s launch. “With Emulate3D Factory Test, manufacturers can now test, iterate and optimise their automation systems with greater accuracy and efficiency — before a single piece of equipment is installed.” In the confectionery context, this


capability is significant because high-speed production lines often consist of hundreds


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