What question did this study set out to answer?

The aim is to enhance energy efficiency and scheduling in food manufacturing using a hybrid digital twin approach.

February 16, 2026Open Access

Closed-Loop Digital Twin for Energy-Efficient Scheduling in Food Manufacturing Systems

GAGulshat AmirkhanovaAl-Farabi Kazakh National University NYNazly YusubovaAl-Farabi Kazakh National University BABauyrzhan AmirkhanovAl-Farabi Kazakh National University

Key Points

The aim is to enhance energy efficiency and scheduling in food manufacturing using a hybrid digital twin approach.
Developed a Hybrid Digital Twin Architecture (HDTA) with three layers: simulation, optimization, and edge control.
Applied the architecture to a bakery model with 10 different products.
Utilized simulation and constraint programming for effective scheduling decision-making.
Achieved a 24.4% reduction in production time.
Resulted in 23% energy savings during the manufacturing process.
Eliminated quality time-window violations completely (0.0% vs. 13.3% baseline, p < 0.001).
Demonstrated a return on investment of 2.4 months.

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.

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