PepsiCo: Boosting Efficiency with Siemens Digital Twin Tech

Food and beverage manufacturer PepsiCo is demonstrating how cutting-edge digital technology could transform production efficiency, after trialling new industrial metaverse capabilities at its US facilities.

PepsiCo has been working with Siemens to test Digital Twin Composer technology at selected manufacturing and warehouse sites, identifying up to 90% of potential issues before physical construction. The collaboration has also delivered faster design cycles and reduced capital expenditure, showcasing the potential applications for the food and drink sector.

According to Siemens, the technology delivers what it calls "true industrial intelligence" by combining physical AI with comprehensive digital twin capabilities. The platform enables organisations to apply industrial AI, simulation and real-time physical data to make decisions virtually, at speed and at scale.

Converting facilities into digital twins

The partnership between the two companies has seen PepsiCo convert selected US manufacturing and warehouse facilities into high-fidelity 3D digital twins. These simulate plant operations and the end-to-end supply chain to establish a performance baseline for the beverage manufacturer's operations.

According to Siemens, teams were able to optimise and validate new configurations to boost capacity and throughput within weeks. This gave PepsiCo a unified, real-time view of operations with flexibility to integrate AI-driven capabilities over time.

Using Siemens' Digital Twin Composer alongside NVIDIA Omniverse and computer vision technology, PepsiCo can now recreate every machine, conveyor, pallet route and operator path with physics-level accuracy. The system enables AI agents to simulate, test and refine system changes before any physical implementation takes place.

Measurable improvements in production efficiency

The technology has delivered a 20% increase in throughput on initial deployment. It is also driving faster design cycles, nearly 100% design validation and 10-15% reductions in capital expenditure by uncovering hidden capacity and validating investments in a virtual environment before committing resources.

Digital Twin Composer builds what Siemens calls Industrial Metaverse environments at scale. Industrial companies can combine 2D and 3D digital twin data from Siemens's digital twin with physical real-time information in what the company describes as a "managed, secure real-time photorealistic visual scene". The environment is built using NVIDIA Omniverse libraries.

"With Digital Twin Composer, companies can rapidly build and maintain this global environment, containing all aspects of their product or production data (both virtual and physical) in a secure, managed high-fidelity 3D experience, throughout the lifecycle of the product, process or facility," Siemens says.

The company adds that Digital Twin Composer provides contextualised, real-time insights and intelligence enabling companies to visualise, interact with and iterate on any product, process or factory in its real-world context before physical design or construction.

Broader implications for manufacturing

Joe Bohman, Executive Vice President (EVP), PLM Products, Siemens Digital Industries Software, says: "The new Digital Twin Composer delivers on our vision for the industrial metaverse.

"It helps manufacturers to overcome the unprecedented challenges of mastering complexity, accelerating production, reducing costs and increasing profitability.

"Siemens and NVIDIA are partnering to help manufacturers bring the most complex products, processes and factories online faster, boost resiliency and sustainability, and continuously optimise performance."

Rev Lebaredian, Vice President (VP) of Omniverse and Simulation Technology, NVIDIA, adds: "In an era where every physical object and process will have a digital twin, Siemens' Digital Twin Composer establishes a digital thread that connects the silos of design, engineering and operations across the Siemens Xcelerator ecosystem.

"By integrating NVIDIA Omniverse libraries into Digital Twin Composer, enterprises can take advantage of physically accurate simulation across their workflows to validate their entire lifecycle – from product design to factory logistics – in the virtual world before committing a single atom to the real one."

Launched at CES 2025, Siemens' Digital Twin Composer is currently in early access with select customers, with PepsiCo's involvement demonstrating potential applications for food and beverage manufacturers seeking to optimise production and reduce costs.