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Key technology for the digital transformation of industrial plants and processes

The idea of the digital twin

By linking to real-time data, such as from sensors, control systems, or operating software, the digital twin enables precise representation, analysis, and optimization of the real world in the digital environment.

Next-Level Industry Intelligence

How does a digital twin work?

A digital twin is created by intelligently linking various data sources to form a dynamic, digital representation of a physical object, system, or process.

It combines structured and unstructured information in a common model. This enables the digital twin to deliver insights in real time, simulate future scenarios, identify potential for improvement, and automatically document all steps.

The result is a complete, dynamic “mirror” of the physical system – across all phases: from planning and operation to optimization and decommissioning.

Understanding the current situation

Objective: Real-time monitoring and visual control of physical assets, processes, or facilities.

A digital twin continuously collects data from sensors, control systems (e.g., SCADA), machines, and external sources (e.g., weather, energy supply). This data is consolidated in a central model and clearly displayed

in the form of:

  • 2D/3D visualizations (e.g., plant layouts, P&IDs, building plans)
  • Measurement value dashboards (e.g., temperature, pressure, vibration, flow)
  • Real-time status (e.g., “open/closed,” operating states, warning messages)

Benefits:

  • Better understanding of the plant
  • Faster identification of malfunctions
  • Transparency regarding decentralized or difficult-to-access assets

Safely testing hypothetical scenarios

Objective: To test in advance how systems react to certain changes.

The data integrated in the digital twin can be used to perform virtual tests without affecting real systems. The simulation is based on mathematical models, physical parameters, or machine learning algorithms.

Typical use cases:

  • Stress tests (e.g., what happens in the event of high load or total failure?)
  • Production planning (e.g., what is the impact of a changed process?)
  • Energy efficiency analyses (e.g., how can energy consumption be optimized?)

Benefits:

  • Reduction of planning errors
  • Risk-free validation of process changes
  • Better preparation for exceptional situations

Improve performance, avoid downtime

Goal: Reduce operating costs, make processes more efficient, extend service life.

The digital twin analyzes historical and current data and identifies optimization potential using rules, trend analyses, or AI-based pattern recognition.

These include:

  • Predictive maintenance: Maintenance based on condition data instead of fixed intervals.
  • Bottleneck identification: Detection of inefficient processes or resources.
  • Performance tuning: Analysis and comparison of target/actual deviations.

Benefits:

  • Reduced downtime.
  • Lower resource consumption.
  • More sustainable and resilient plant management.

Complete lifecycle tracking

Goal: Complete history across the entire life cycle.

The digital twin not only maps the current status, but also stores all events and changes in a traceable manner.

This includes:

  • Version and change statuses (e.g., for P&IDs or plant documentation)
  • Maintenance logs and test reports
  • User actions, alarms, malfunctions, and feedback

Benefits:

  • Audit-proof chain of evidence
  • Support for audits and certifications
  • Knowledge transfer during personnel changes or outsourcing
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UDiTH - The Universal Digital Twin Hub

Why digital twins are transforming industry

Industrial digitalization is at a turning point: the use of digital twins is opening up completely new possibilities for dealing with increasing system complexity, data abundance, and global competitive pressure. Instead of relying solely on historical data or isolated solutions, digital twins can be used to map, analyze, and optimize real-world plants, processes, and infrastructures in real time.

This is where UDiTH – Universal Digital Twin Hub – comes in:
As a powerful platform, UDiTH connects all relevant information – from 3D models, P&IDs, and laser scans to sensor values, SCADA systems, and documentation – and creates a living, central digital twin across the entire industrial lifecycle.

Get to know UDiTH - digital twin software

Digital Twins driving innovation across industries.

Core industries for digital twin software

Digital Twin technology is no longer limited to a single field – it is transforming entire industries by making operations more transparent, efficient, and resilient. From design and production to operation and optimization, key sectors already rely on digital twins to gain competitive advantage.

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The digital twin in the industrial lifecycle

Digital twins create
end-to-end transparency

Digital twin software provides data-driven analytics and real-time insights that enable executives and operators to make informed decisions. Risks and errors can be identified early on and proactively avoided, improving asset availability and product quality.

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Frequently asked questions about
Digital Twin Software

A Digital Twin is a virtual representation of a real object, system, or process. It is fed with real-time data from sensors, IoT, SCADA, or ERP systems to monitor, simulate, and optimize the condition, behavior, and performance of its physical counterpart.

Digital Twins are used for monitoring, simulation, optimization, and documentation. Typical applications include production plants, energy grids, buildings, vehicles, infrastructure projects, and complex manufacturing processes. UDiTH, developed by the German software company CAXperts, is one of the most comprehensive solutions available and is recognized as an industry standard for Digital Twin implementations.
  • Faster, data-driven decisions
  • Reduced downtime through predictive maintenance
  • Virtual planning and simulation of projects
  • Complete documentation and compliance
  • Safe training and risk-free scenario testing
  • Integration of multiple data sources in a central platform

Core industries for Digital Twin Software include manufacturing, energy, automotive, construction, infrastructure, logistics, healthcare, and life sciences. In general, Digital Twin technology can be applied wherever complex processes and assets need to be digitally represented.

  • Structural data: CAD/3D models, P&IDs, technical drawings
  • Documentation: manuals, inspection reports, specifications
  • Real-time data: sensor readings, condition information, IoT or SCADA data
  • Historical data & context: maintenance records, events, and asset history
Modern Digital Twin platforms support interfaces to ERP, SCADA, CMMS, and IoT systems. Data can be consolidated, visualized, and analyzed without breaks or redundant entry.

Many platforms like UDiTH  offer web and mobile access, including offline functionality. Inspections, maintenance, and training can be conducted directly on-site.

Digital Twins allow designs and processes to be tested virtually. Changes can be evaluated safely, bottlenecks identified, and resources efficiently planned.

A standard viewer typically only displays 3D models. A Digital Twin, however, combines 3D visualization, real-time data, analytics, simulation, and lifecycle management in a central platform.