At Interpack 2026, Rockwell Automation Inc. is presenting a fully virtualized manufacturing line that illustrates how digital twin technology is reshaping industrial operations. The demonstration highlights how food and beverage manufacturers can design, simulate, and optimize entire production systems before physical deployment.

At a time when manufacturers are under pressure to increase efficiency while reducing operational risk, Rockwell Automation is using Interpack 2026 to make a case for digital-first production design. The company’s showcase centers on a virtual cookie production and packaging line—a detailed simulation that mirrors real-world industrial environments from raw material processing to final palletizing.

The concept is straightforward but powerful: a digital twin is a virtual replica of a physical system that allows manufacturers to test, validate, and optimize operations in a simulated environment. In Rockwell’s implementation, the entire production lifecycle—mixing, baking, cooling, packaging, and logistics—is modeled as a unified, data-connected system.

This approach addresses a long-standing challenge in manufacturing. Processing and packaging have traditionally been engineered as separate systems, often leading to inefficiencies, integration issues, and delayed time-to-market. By contrast, a digitally connected environment enables these functions to be designed as a single operation from the outset.

The demonstration is powered by Emulate3D, Rockwell’s digital twin platform, combined with hardware innovations such as iTRAK intelligent track system. Together, these technologies simulate real machines and production assets, allowing engineers to evaluate system performance under various conditions before installation.

In practical terms, virtualization changes how manufacturing projects are executed. Engineering teams can work in parallel rather than sequentially, validating mechanical, electrical, and automation designs simultaneously. This reduces costly rework, shortens commissioning timelines, and improves collaboration between engineering, operations, and maintenance teams.

The system also reflects a broader shift toward open, scalable architectures. Rockwell’s virtual production line integrates equipment from multiple OEMs—including processing, packaging, and palletizing providers—into a single digital environment. This multi-vendor approach mirrors real factory conditions, where interoperability is often a critical barrier to efficiency.

At the core of this integration is a unified data layer. Platforms like FactoryTalk Optix act as a central source of truth, enabling data from different machines and systems to be standardized and shared. This data foundation supports not only simulation but also real-time monitoring, quality control, and traceability.

Cybersecurity is another critical component. As manufacturing systems become more connected, the attack surface expands. Rockwell addresses this with solutions such as SecureOT platform, which embeds layered protections into the operational technology stack.

The implications extend beyond engineering efficiency. A connected, data-enabled production line creates the conditions for advanced analytics and AI applications. Once systems are unified, manufacturers can apply machine learning models to optimize throughput, predict maintenance needs, and improve product quality.

This convergence of digital twins, data platforms, and AI is part of a larger industrial transformation. Companies like Microsoft and Amazon have already demonstrated how cloud-based architectures can scale data-driven operations. In manufacturing, similar principles are now being applied to physical production environments.

According to Gartner, digital twins are expected to become a foundational element of industrial operations, with a growing percentage of large manufacturers adopting the technology to improve asset performance and operational resilience. Meanwhile, IDC estimates that investments in digital transformation technologies—including simulation and AI—will continue to grow at double-digit rates across industrial sectors.

For enterprise manufacturers, the value proposition is increasingly clear. Digital twins reduce risk by allowing systems to be tested before deployment. They accelerate time to value by shortening development cycles. And they enable continuous optimization by providing a real-time feedback loop between physical and digital environments.

Still, adoption is not without challenges. Building accurate digital twins requires high-quality data, standardized interfaces, and collaboration across multiple stakeholders. Many organizations also need to modernize legacy systems to fully integrate with digital platforms.

Rockwell’s demonstration at Interpack suggests that these barriers are gradually being addressed. By combining simulation, data architecture, and partner ecosystems into a cohesive offering, the company is positioning digital twins not as a niche tool, but as a central component of modern manufacturing strategy.

As the industry moves toward more connected and intelligent operations, the ability to design and optimize production systems in a virtual environment may soon become a baseline requirement rather than a competitive advantage.

Market Landscape

Digital twin technology is rapidly gaining traction across industrial sectors, particularly in food and beverage manufacturing where efficiency, traceability, and compliance are critical. Vendors are increasingly integrating simulation tools with data platforms and AI capabilities, creating unified environments that support the entire production lifecycle.

This trend aligns with the broader shift toward Industry 4.0, where physical operations are augmented by digital intelligence. As manufacturers adopt cloud, IoT, and advanced analytics, digital twins are emerging as the bridge between design, execution, and optimization.

Top Insights

• Rockwell Automation’s virtual production line demonstrates how digital twins can unify processing and packaging, enabling manufacturers to design, simulate, and optimize entire operations before deployment.
• The use of Emulate3D and iTRAK systems highlights how simulation and smart hardware integration can reduce engineering risk and accelerate commissioning timelines in complex manufacturing environments.
• Open, scalable data architectures powered by platforms like FactoryTalk Optix enable seamless integration of multi-vendor systems, improving interoperability and operational visibility.
• Embedded cybersecurity through SecureOT reflects the growing importance of protecting connected industrial systems as data-driven manufacturing expands.
• Digital twins are becoming central to Industry 4.0 strategies, enabling AI-driven optimization, predictive maintenance, and real-time performance monitoring across production lines.

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