Virtual Twins and Biomanufacturing: An Exploration of Development and Validation

In the evolving era of Industry 4.0, the power of Virtual Twin technology is proving to be an increasingly valuable tool in biomanufacturing. Offering a unique combination of high-resolution simulation and insightful data analysis, this revolutionary technology is drastically transforming traditional manufacturing processes, extending its reach into every aspect of the industrial landscape. 

By creating an intricate digital replica of physical system, Virtual Twin technology allows biomanufacturers to simulate, analyze, and optimize various production and process engineering scenarios in a realistic 3D environment. The impact of this advancement ranges from streamlined recipe management to efficient line qualification and commissioning. Let’s delve deeper into the way Virtual Twin technology is revolutionizing the biomanufacturing sector. 


Recipe Management with Virtual Twins: A Game-Changer 

Traditionally, recipe management has been a time-consuming process, characterized by a considerable amount of trial and error. Such procedures often lead to inefficient resource usage and extended time to market for new products. However, with the integration of Virtual Twin technology, manufacturers are finding new ways to revolutionize the recipe development process. 

  • Accelerate Product Development: Virtual Twin technology enables manufacturers to test and release new recipes in a simulated environment. By doing so, the time taken to bring a new product to the market is dramatically reduced, while the rate of innovation increases. 
  • Promote Sustainable Recipe Development: The use of Virtual Twin technology also promotes more sustainable recipe development techniques. Manufacturers can simulate various process parameters and observe their impacts on the environment and resource utilization. This fosters a more sustainable approach towards the environmental footprint. 
  • Enhance Quality and Efficiency: Identifying potential issues early in the development phase is another advantage of Virtual Twin technology. It minimizes the risk of costly late-stage failures and helps to optimize the overall process, ensuring a higher quality of output. 

Process Engineering for Biomanufacturing: Harnessing the Power of Virtual Twins 

In the field of process engineering, Virtual Twins are rapidly becoming an essential tool. By creating an accurate digital representation of a physical system, manufacturers can explore the behavior of intricate multi-physics systems, which might otherwise be too complex or costly to analyze. 

  • Comprehensive Understanding and Early Issue Prediction: Virtual Twin technology allows manufacturers to define, simulate, and validate complex process dynamics, offering a comprehensive understanding of the system’s behavior. This way, manufacturers can predict potential issues and make necessary adjustments early on, avoiding significant issues down the line.  
  • Enhance Efficiency and Productivity: By using Virtual Twin technology, manufacturers can also simulate the interaction of different process variables. This makes It possible to adjust these variables optimize overall performance, thereby enhancing efficiency and productivity. 
  • Cost and Waste Reduction: Another critical advantage of Virtual Twin technology is the reduced reliance on physical prototypes. This leads to significant savings in terms of material costs and waste reduction, promoting a more sustainable manufacturing approach. 

Line Model & Simulation: Orchestrating Optimal Efficiency for Biomanufacturing 

Optimizing plant layout is another area where Virtual Twin technology proves its worth. It aids manufacturers in synchronizing all engineering processes, simulating production scenarios, and designing ergonomic plant layouts. 

  • Seamless Alignment and Increased Efficiency: Virtual Twin technology helps to align all engineering processes seamlessly. This reduces the need for coordination efforts, saving valuable time and resources while increasing the efficiency of the manufacturing process. 
  • Streamline Operations and Boost Productivity: The ability to simulate and optimize production scenarios is another key benefit of Virtual Twin technology. It allows manufacturers to predict potential bottlenecks and inefficiencies in the production workflow, helping to streamline operations and boost productivity. 
  • Enhance Worker Safety: The technology also enables the creation of ergonomic plant layouts. A well-designed working environment promotes worker safety and well-being, which can enhance productivity while reducing potential occupational hazards. 

Line Qualification & Commissioning: A Preemptive Approach to Biomanufacturing

Harnessing the power of Virtual Twin technology in line qualification and commissioning processes brings valuable benefits: 

  • Preemptive Testing and Resource Savings: With Virtual Twin technology, manufacturers can test and validate systems in a simulated environment before implementation in the physical plant. This preemptive measure saves significant resources by reducing the need for reworks and modification after the physical installation of systems. 
  • Informed Decision-Making and Smoother Implementation: Virtual Twin allows manufacturers to understand the operational capabilities and limitations of a system in advance. This foresight enables more informed decision-making when it comes to system selection and design, ensuring a smoother transition from design to implementation. 
  • Risk Reduction and Increased Reliability: Lastly, the use of Virtual Twins helps reduce the risk of system failures and unexpected downtime during production. By detecting potential system failures in advance, manufacturers can ensure more robust and reliable production processes. 


The Path Forward

Virtual Twin technology is revolutionizing biomanufacturing by enhancing workflow efficiency, minimizing risks, and facilitating resource optimization. As a potent tool for sustainable manufacturing, it’s poised to drive further transformations in the sector as it evolves. With increasing process complexities, its adoption is critical, providing manufacturers the means to remain competitive, innovate, and foster sustainable practices. 


TriMech Enterprise Solutions Virtual Twin Technology on the 3DEXPERIENCE Platform 

By leveraging Virtual Twin technology on the 3DEXPERIENCE platform, you can instantly gather valuable insight into the real-world performance of products and processes to improve operational resiliency, reduce costs and gain a competitive advantage with cloud-based manufacturing solutions. Contact us to learn more.