Executive Summary
The implementation of digital twins in manufacturing has become a vital component of Industry 4.0. It enables real-time simulation, resource optimization, and predictive analysis to enhance efficiency and reduce operational risks.
To harness these benefits, Krones, the global process manufacturing line provider for bottling, canning, and packaging, developed in just two months a physically accurate digital twin application with AI to simulate beverage production processes.
Leveraging expertise and technologies from Ansys (part of Synopsys), CADFEM, Microsoft, NVIDIA, and SoftServe, Krones achieved accurate fluid dynamic simulations in under 30 minutes per cycle — driving resource and process optimization. That has accelerated its digitalization strategy and set a new standard for rapid technology adoption in manufacturing.
Why Krones Needed Enhancements to Their Simulations
Krones, renowned for developing and providing complete production solutions for food and beverage manufacturers, encountered a limiting obstacle: time-consuming fluid simulation methods developed decades ago. Liquid dynamics in manufacturing are inherently fast-paced and unpredictable, requiring precise management at every stage. Velocity, machine and bottle design, and flow dynamics create significant challenges for controlling and simulating uncapped bottles, as every variable — including pressure, flow, and turbulence — must be meticulously controlled and predicted.
The inability to optimize these factors can lead to excessive waste, inefficiencies, and operational problems during subsequent phases, making advanced simulation technologies essential for maintaining efficiency and minimizing losses. But evaluating liquid dynamics in bottling and filling lines demanded two to four hours per simulation, restricting both innovation and the speed of operational upgrades.
Overcoming this pressure point became more urgent as market expectations shifted toward digital, data-driven manufacturing. Realizing the immediate need to transition from legacy workflows to comprehensive digital processes, Krones set clear priorities: cut simulation times, empower real-time decision making, and double down on the company's commitment to advanced industry practices.
The 2-Month Transformation: Digital Twins for Fluid Dynamics Simulation
With these priorities, Krones kicked off a multi-partner effort for a rapid engagement — focused not on abstract planning, but on tangible results. In just two months, Krones developed an application that enables modeling, visualization, and optimization of complex fluid behavior, encompassing both fluid dynamic simulation and filling machine simulation.
The result: a digital twin equipped with AI. The digital twin digitally maps the physical world down to the smallest detail. The use of AI and cloud computing enables insights for liquid processing optimization, so Krones’ manufacturing customers can produce their products more efficiently, sustainably, and productively.
