Most manufacturers judge high-throughput performance for material handling by machine speed or a specific system’s capacity. But in reality, that’s not the case. Throughput hinges on how effectively materials move through the system as a whole.
Small inefficiencies in material flow can quickly create congestion, disrupt downstream processes and reduce overall performance. These problems are especially evident in facilities where multiple automation technologies such as conveyors, palletizing systems, robotic cells and storage solutions must work in coordination.
To manage this complexity, digital twin technology is one of the most practical and effective solutions. It creates a virtual representation of material movement across the entire operation so that manufacturers and distribution operators better understand how systems interact, where constraints develop and how changes will impact flow before they are implemented on the shop floor.
Material flow defines throughput better than speed
In many instances, warehouses will focus their efforts on optimizing production systems only at the equipment level. They select machines based on their speed, size conveyors for expected capacity and design storage systems to meet anticipated demand.
However, real-world performance depends on how well these elements work together and will likely involve some costly trial and error to ensure they do. For example, a high-speed production line is unable to deliver value if downstream systems fail to absorb its output. Similarly, automated storage or palletizing systems can become underutilized if upstream flow is inconsistent or poorly synchronized.
The result is a common but costly situation: materials accumulate in some areas while others remain idle. Unfortunately, these imbalances often go undetected during the design phase and only become apparent once the system is fully operational.
Digital twins, on the other hand, address this uncertainty by virtually modeling material movement across the entire production line. Instead of evaluating equipment in isolation, they simulate how materials travel through interconnected processes to reveal where flow is interrupted or constrained.
Where material flow breaks down
Breakdowns in material handling rarely occur at a single point. Instead, they emerge at the intersections between systems.
Examples include:
These issues are often interdependent. A delay in one area can have ripple effects across the system, creating inefficiencies that are difficult to trace without a holistic view. Traditional layout planning tools are limited in their ability to capture these dynamics. Static models and isolated simulations may show that individual systems function correctly, but they do not fully represent how variability in flow impacts overall performance.
Digital twins provide a more complete perspective by simulating real operating conditions, including variability in demand, timing and system interaction.
From static design to dynamic simulation
Historically, facilities design material handling layouts using static data of throughput and utilization. While this approach is effective for defining baseline capacity, it is unable to account for the inevitable variability that comes up in real-world operations.
By modeling how materials move through conveyors, buffers, automated storage systems and manual touchpoints, a digital twin allows manufacturers to evaluate performance under various operating scenarios. This includes changes in demand profiles, variations in production output and equipment downtime or delays.
By testing these conditions virtually through a digital twin, operators can identify where congestion is likely to occur and adjust system design before physical implementation. This reduces the risk of costly rework and improves confidence in system performance. READ MORE
by Graham Wloch
Source: automation.com
Packaging group SIG has announced that its chief financial officer, Ann-Kristin Erkens, will take on the role of chief executive officer, effective immediately. Erkens previously served as SIG’s interim CEO from August 2025 to end of February 2026. She will take over from current CEO Mikko Keto, who took up the position in spring 2026, and will continue to serve as CFO until a successor has been appointed.
Ardagh Holdings is preparing for a potential sale of some or all of its approximately 76% stake in Ardagh Metal Packaging to a third-party buyer. The process could also see Ardagh acquire the remaining Ardagh Metal Packaging shares before facilitating a sale of the entire metal packaging business.
Sonoco is again restructuring its business units and bringing the entire global consumer packaging workforce under a single, integrated leadership structure. Ernest Haynes will be the president of global consumer packaging. Haynes will report to CEO Howard Coker and will be responsible for Sonoco’s largest global business, overseeing operations in 25 countries covering 11,250 employees and $5.2 billion worth of annual sales.
