Advances in Food Science, Processing and Technology

Digital Twins in Food Manufacturing

Digital twin technology is transforming food manufacturing by enabling virtual replicas of physical production environments. These digital models mirror real-time operations, capturing data from sensors, machines, and systems to simulate, predict, and optimize processes. By creating a dynamic representation of production lines, manufacturers can analyze performance, test changes, and forecast outcomes without interrupting operations. Applications include predictive maintenance, quality control, energy efficiency, and waste reduction. Digital twins support decision-making by providing insights into process deviations, equipment wear, and product consistency. In R&D, they facilitate rapid prototyping and scaling of new recipes or formulations. Integration with AI and IoT further enhances the system's intelligence and responsiveness. As supply chains become more complex, digital twins enable greater visibility and agility, ensuring consistent quality and regulatory compliance. With benefits spanning cost savings, sustainability, and innovation, digital twin technology is becoming a foundational element of the future smart food factory.