BISCUIT AND COOKIE PRODUCTION
The important caveat is that the accuracy depends on the quality
of the inputs. A virtual environment can reveal integration risks very effectively, but much better if OEMs provide sufficiently detailed models, control interfaces, machine behaviours and data structures. If the model is simplified, it will still be useful for concept validation, but less reliable for detecting edge-case commissioning problems.
3.What’s the biggest blind spot companies still have with digital twins? “For a cookie manufacturer adopting virtual commissioning for the first time, where do projects still tend to fall short despite using tools like Emulate3D?” The biggest gap in understanding is treating digital twins and virtual
commissioning as one-time engineering projects, rather than part of a continuous business and operations strategy. For a cookie manufacturer, Emulate3D technology
can effectively simulate production lines, validate controls, and reduce commissioning risk. However, projects are most successful when the digital twin is aligned with clearly defined business objectives, such as faster startup times, smoother changeovers, reducing waste, enhancing operator readiness, or enabling long-term line optimisation. A common challenge is that organisations focus
example. By using FactoryTalk Optix to build Intuition, an on-machine performance monitoring solution, Convergix helped customers standardise contextualised data collection and create more immediate visibility into machine performance. This enabled capabilities such as remote support, machine-to-machine comparisons, plant-level visibility, and AI-ready time-series analysis. For operators, the value is immediate because the architecture does
more than collect data, it makes data easier to understand and act on. From the first actionable view, teams can monitor how the line is performing, identify performance trends early, compare assets, and make more proactive decisions that support uptime, throughput, and continuous improvement. In this way, unified data architecture creates value from day one while also establishing the foundation for more advanced capabilities over time, including predictive maintenance, machine learning, autonomous decision-making, and enterprise-wide optimisation.
TOGETHER, STUDIO 5000 AND THE EPLAN INTEGRATION WERE
heavily on building the model itself but underestimate the broader operational factors that influence success. Workforce training, legacy equipment integration, plant-floor variability, cybersecurity, and ongoing model ownership all play a critical role. Without early involvement from operators, maintenance personnel, and production leaders, a digital twin may perform well in a virtual environment but fail to deliver full potential once deployed on the factory floor. The shortfall usually comes from strategy, siloed implementation, and a lack of planning for how the twin will evolve beyond the first commissioning project.
ALREADY DELIVERING 10– 15% REDUCTIONS ACROSS THE ENTIRE PROJECT
5.What does ‘good’ OEM collaboration look like in practice? “You mentioned PartnerNetwork—what separates a high-performing multi-vendor project from one that struggles, especially when aligning processing, baking, and packaging systems?” In a multi-vendor project connecting processing,
baking and packaging systems, a project that struggles often has each OEM working in isolation, using separate control logic, proprietary interfaces and disconnected data. Integration problems then appear late during commissioning, when they are costly to fix. A high-performing project is different. The OEMs
4. How does unified data architecture translate into day-one operational value? “With platforms like FactoryTalk Optix, what are the first actionable insights operators or plant managers can expect when the line goes live—not months later?” Unified data architecture translates into day-one operational value
by giving operators and plant managers access to clean, contextualised, decision-ready data as soon as the line goes live. Rather than waiting for a later analytics phase, teams can start with a common view of machine and process performance across equipment, controllers, and sites. Rockwell Automation’s case study on Convergix is a useful
and system integrators align early on a common control architecture, shared standards such as PackML or OPC UA, and consistent data requirements. Machines are delivered as DataReady™ solutions, so operators can view performance, diagnostics and OEE across the whole line rather than siloed equipment or standalone machine units. Strong teams also test integration virtually before equipment arrives
on site, using tools such as Emulate3D to simulate hand-offs, timing, throughput and bottlenecks. This reduces commissioning risk and helps ensure the line works as one system. This is where Rockwell Automation’s PartnerNetwork adds
value; it brings OEMs, integrators and technology partners into a pre-aligned ecosystem with shared technical competencies and execution frameworks. In practice, the best multi-vendor projects should operate as one
integrated processing, baking and packaging line, rather than three separate machines working together.
AUGUST/SEPTEMBER 2026 • KENNEDY’S BAKERY PRODUCTION • 23
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