Krones: Using Digital Twins in Beverage Manufacturing

Krones implements digital twins that incorporate AI agents, combining physically accurate real-time simulations with artificial intelligence that can reason and make decisions independently.

The technology is developed through collaboration with CADFEM, Microsoft, NVIDIA and SoftServe, with Krones stating its ambition is to "set a new standard" for digital transformation in manufacturing.

The technology addresses the complex demands of fluid processing, which requires precise coordination of continuously changing physical processes. These include filling speed, bottle design and fluid dynamics. Real-time monitoring, prediction and optimisation of parameters such as pressure, flow and turbulence are essential to prevent waste or disruptions downstream.

According to Krones, the digital twins have fundamentally transformed its machine and plant simulations within a two-month period. Working with its partners, the company has created a physically accurate digital twin application that can complete simulations in under five minutes, compared to the three to four hours previously required.

The application uses high-precision physics simulations to model liquid behaviour during filling processes. This enables the design and interaction with physically accurate virtual replicas of bottling facilities in real time, accelerating decision making and optimisation in bottling operations.

Gabriele Eder, General Manager Manufacturing at Microsoft Germany, says: "With our trusted Microsoft Azure, Krones accelerates and scales its innovations through AI-powered tools and technologies.

"Together, we're creating the solutions of today and the breakthroughs of tomorrow."

Autonomous configuration optimisation

The digital twin application can autonomously learn which configurations produce optimal results. These solutions are then transferred directly to physical machines, which enables real-time comparisons, instant implementation of optimisations and more efficient resource use.

Naomi Betz, Senior Account Manager, Manufacturing and Industry (DACH) at NVIDIA, says: "With real-time digital twins powered by OpenUSD, NVIDIA Omniverse libraries and accelerated computing, Krones is pioneering a new era of precision engineering."

Universal Scene Description (OpenUSD) was invented by Pixar Animation Studios and includes a collection of fundamental components and capabilities that accelerate workflows, teams and projects, according to NVIDIA. The technology enables AI development in 3D worlds.

Shift from human-guided systems

Markus Tischer, Member of Krones' Executive Board, says: "With the Agentic Digital Twins, we are demonstrating that digitalisation and AI are not just visions for the future but deliver tangible efficiency gains and sustainable benefits today.

"Together with our partners, we are setting new benchmarks for the beverage industry."

The technology could represent a significant shift for the manufacturing sector. Previously, digital twins have operated in close collaboration with human expertise and judgment, with operators required to guide decisions and interpret results.

This new generation of digital twins uses autonomous reasoning, decision-making and action capabilities to respond to real-time data and trigger workflows automatically, marking a departure from traditional human-guided systems.