Suryon applied a digital twin approach to a filling–capping–labeling line for household cleaning products. Product/format scenarios were validated before deployment, and commissioning was de-risked through virtual commissioning with a live performance dashboard.

Scope

• Modeling & Simulation: Time/flow model for filler, capper (torque), labeler and conveyor buffers.
• Data & Integration: Twin synchronized with PLC/SCADA signals (flows, valve timing, temperatures, cap torque, conveyor speeds, vision pass/fail, downtime causes).
• Changeover Optimization: Scenario testing for bottle/cap/label formats; speed, torque window and label alignment tuned to recipes.
• Virtual Commissioning: PLC/HMI logic validated on the twin to minimize on-site trial-and-error.

Project Summary

• Line Type: Liquid filling + capping + labeling (household cleaners)
• Our Role: Digital-twin modeling, data integration, virtual commissioning, changeover optimization

Benefits (scenario tests & general outcomes)

• Product/format changes validated without stopping production.
• Filling accuracy, cap torque, label alignment improved prior to go-live.
• Bottlenecks and root causes surfaced early; line flow balanced.
• Commissioning risk and uncertainty reduced; on-site tuning shortened.
• Unified performance dashboard enabled faster, aligned decisions.
• Changeover steps standardized; training and know-how transfer eased.
• CIP/cleaning and energy alternatives compared transparently.