Improved visibility and understanding without requiring access to the physical asset
Reduced operational costs
Dry runs and simulation-based commissioning minimize on-site adjustments and downtimes
Enhanced process efficiency
Digital Twin process changes accelerate physical implementation
Improved operator qualification
Realistic, offline HMI training reduces live operation errors
Application
Advanced equipment simulation model to maximize Overall Equipment Effectiveness (OEE)
Optimized equipment simulation model
The SKAN Digital Twin provides a high-fidelity virtual replica of the equipment line, enabling you to reduce reliance on physical assets during both early project phases and ongoing operations.
For operator training
The Digital Twin enables immersive, simulation-based training in a fully virtual environment, accelerating operator readiness while minimizing disruption to production.
Change Management optimization
The Digital Twin supports efficient evaluation and implementation of change requests independent of physical equipment, reducing risk and improving decision-making speed.
Process
From concept to a continuously optimized Digital Twin
1
Requirements definition
Together, we define your objectives – whether simulation, training, or validation and develop a tailored solution.
2
Model creation
A detailed digital model of your isolator or process is built based on real equipment data (CAD model, PLC program, etc.).
3
Implementation of the Digital Twin
Implementation and commissioning of the Digital Twin onsite is supported by SKAN Digital Twin experts.
4
Simulation and analysis
Process simulations, optimizations, or changes can be performed on the Digital Twin prior to implementation on the physical asset.
5
Training
The Digital Twin can be used for operator training without disrupting the production of the real equipment.
Service highlights
Your equipment. Perfected virtually.
Accelerate process optimization
Simulating process changes on the Digital Twin accelerates their implementation on the physical equipment, increasing overall production uptime. It enables validation of process optimizations before deployment, reducing trial-and-error iterations on the real system.
Advanced equipment visibility
The high-resolution digital model improves visibility and understanding of the equipment without requiring access to the physical asset. It allows users to explore equipment behavior, interactions, and constraints in a risk-free environment, supporting better technical decision-making.
Cost-efficient operation
Simulation-based commissioning and dry runs minimize on-site adjustments and reduce unexpected downtime. This approach also decreases the need for physical testing resources and shortens commissioning timelines, leading to measurable cost savings.
Neutral-format CAD models drive lifelike motion of all moving parts
PLC emulation
The control code runs unchanged in the virtual controller, maintaining identical I/O interactions
Behavioral and process modeling
Sensor logic, physical process simulation, and safety interlocks are fully replicated
HMI integration
Operator panels, alarm sequences, and user workflows operate in the virtual environment just as on the shop floor
FAQs
A Digital Twin enables the simulation of qualification and operational scenarios in a virtual environment. This reduces repeated on-site testing, shortens qualification timelines, and accelerates time-to-market while maintaining compliance.
With a one-to-one representation of equipment behavior, a Digital Twin provides a highly realistic training environment. Operators can be trained on normal operations, deviations and critical scenarios without interrupting production, reducing human error and improving OEE.
A Digital Twin is built using a combination of:
Physical design data (e.g. CAD models, airflow characteristics, equipment layout)
Automation data (e.g. PLC programs, control logic, recipes)
Yes. By reproducing specific conditions in a controlled virtual environment, a Digital Twin can generate scientifically sound evidence to support root cause investigations and batch release justification.
No. Digital Twins can also be implemented for existing systems, provided that sufficient design documentation, automation logic, and historical data are available.
