Closed-Loop Digital Twin for Energy-Efficient Scheduling in Food Manufacturing Systems
Abstract
Food manufacturing faces challenges in balancing efficiency, energy use, and quality. This paper presents a Hybrid Digital Twin Architecture (HDTA). It combines simulation, constraint programming, and Industrial IoT into a closed-loop system. The architecture has three layers: simulation for planning, optimization for scheduling, and an edge layer for control. We validated this using a bakery model with 10 products. The results show a 24.4% reduction in production time and 23% energy savings. Simulation results show complete elimination of quality time-window violations (0.0% vs. 13.3% baseline, p < 0.001). The system achieved a 2.4-month return on investment. This work demonstrates how combining these technologies can improve process industries.
Fields of Study & Subjects
Digital Transformation in Industry
Scheduling and Optimization Algorithms
Flexible and Reconfigurable Manufacturing Systems
Publication details
- Journal / source
- Information
- Publisher
- MDPI AG
- Volume
- 17
- Issue
- 2
- Pages
- 195–195
- Publication date
- 13 February 2026
- Language
- EN