DIGITAL TWINS


of interrelated subsystems. Digital twin testing at scale allows manufacturers to simulate end-to-end operations — from ingredient handling and tempering to wrapping and packing — identifying potential bottlenecks and fault conditions in a virtual space first, which can help ensure smoother physical commissioning. Rockwell Automation’s digital twin


ecosystem has also expanded to include tighter integration between design and simulation workflows. At SPS 2025, Rockwell and engineering software provider Eplan unveiled a digital twin-driven electrical simulation integration that connects schematic design tools with Rockwell’s Emulate3D platform. This integration enables engineers to virtually model, test and optimise electrical systems, automated conveyors and robotic control logic ahead of hardware implementation, reducing engineering time and enhancing accuracy. “This integration empowers engineers


to simulate and validate electrical logic with speed and precision, bridging the gap between design and execution,” said Gunther Saelzer, director of software and control, North Region at Rockwell Automation.


SCALING DIGITAL TWINS TO THE FULL FACTORY LEVEL IS CRITICAL FOR MODERN INDUSTRIAL OPERATIONS, – MATHEUS BULHO,


ROCKWELL AUTOMATION.


The road ahead While still emerging, digital twin technology is poised to become a standard tool in confectionery manufacturing. The convergence of AI, IoT, simulation, and immersive visualisation is creating an environment where the virtual and physical factories work in tandem. For brands racing to innovate with


protein-enriched bars, fibre-fortified chocolates, or functional gummies,


digital twins offer a way to balance complexity with control. By enabling virtual experimentation, predictive optimisation, and scenario testing, confectionery manufacturers can accelerate new product launches, ensure consistent quality, and respond rapidly to shifting consumer trends—all without interrupting production. The virtual factory may soon become as critical to confectionery manufacturing as ovens, moulding machines, or cooling tunnels. Though, despite its promise, the deployment of digital twins in confectionery is not without obstacles. Data integration is a major challenge. Many confectionery factories operate legacy equipment without modern IoT connectivity, limiting the ability to capture real-time process data. In addition, high-fidelity digital twins require both financial investment and a workforce skilled in data science, process engineering, and simulation modelling. “There’s a steep learning curve,” says


Elena Rojas of Blendhub. “Companies need both the software tools and the human expertise to translate data into actionable insights. But the payoff—faster innovation cycles, reduced waste, and improved product consistency—is substantial.”


Siemens unveils Digital Twin Composer at CES 2026, enabling photorealistic virtual factory simulation and industrial metaverse environments. (Image: © Siemens press kit)


MARCH 2026 • KENNEDY’S CONFECTION • 31


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