The role of digital twins in packaging development

By simulating various environmental factors such as temperature, humidity, and impact forces on a digital twin, companies can evaluate the durability of packaging. Credit: Sabura / Shutterstock

D​​​​​​​igital twins are digital copies of physical objects, systems, or processes that help businesses test and improve their designs before making real-world products. In packaging development, this technology allows companies to create virtual versions of packaging to test materials, durability, and environmental impact before production.  

By using real-time data and simulations, businesses can reduce waste, improve efficiency, and develop more sustainable packaging solutions. 

Packaging is a critical part of any product, influencing both functionality and consumer experience. Traditionally, developing new packaging requires multiple prototypes, testing, and revisions, which can be costly and time-consuming.  

Digital twins simplify this process by allowing companies to experiment with different designs in a virtual environment, identifying potential flaws before physical production begins. 

Traditional packaging design relies on iterative prototyping, which can be costly and time-consuming. Digital twins eliminate much of this trial and error by allowing designers to create and test virtual packaging models.  

These models simulate how different materials, shapes, and sealing techniques will perform under various conditions, such as compression, moisture exposure, and transportation stress. 

For instance, digital twin technology enables companies to assess the rigidity of a carton design under stacking pressure without producing a single prototype. This reduces material costs and accelerates the development cycle.  

Additionally, simulations can predict potential weak points in the design, preventing failures that could lead to product damage and customer dissatisfaction. 

In packaging production, digital twins provide real-time monitoring and predictive maintenance capabilities. By creating a digital replica of a production line, manufacturers can analyse machine performance, identify inefficiencies, and predict potential breakdowns.  

This proactive approach reduces downtime and maintenance costs, ensuring that packaging operations run smoothly. 

Moreover, digital twins help optimise supply chains by simulating logistics scenarios. For example, manufacturers can use digital twins to model the impact of different packaging dimensions on pallet efficiency, transport costs, and carbon footprint.  

If a company ships beverages in cartons, digital twins can determine the optimal carton size and arrangement to maximise truck space, reducing fuel consumption and emissions. 

Sustainability is a key concern in modern packaging, and digital twins play a crucial role in minimising environmental impact. By simulating packaging lifecycles, companies can evaluate recyclability, material efficiency, and carbon footprint.  

Digital twins can model the effects of using alternative materials, such as biodegradable plastics or recycled paper, before committing to production.

For example, a food packaging manufacturer may explore the environmental benefits of switching from virgin plastic to a compostable film.

Digital twins allow for testing factors such as barrier properties, shelf life, and degradation rates in different environmental conditions. This ensures that packaging meets performance requirements while aligning with sustainability goals.

Furthermore, regulatory compliance is simplified through digital twin technology. By integrating real-time data from production lines, companies can ensure that packaging meets safety, hygiene, and recyclability regulations.

Automated documentation and traceability features help manufacturers prove compliance with evolving legislation, reducing the risk of costly recalls or penalties.

As digital twin technology advances, its applications in packaging development will expand further. With the integration of artificial intelligence (AI) and the Internet of Things (IoT), digital twins will become even more sophisticated, allowing for greater predictive accuracy and automation. 

For instance, AI-driven digital twins could optimise packaging based on consumer behaviour insights, predicting trends and preferences before they emerge.  

Smart packaging, which includes embedded sensors, could provide real-time feedback on temperature, humidity, and tampering, enabling companies to refine designs dynamically. 

Digital twins are transforming the packaging industry by improving design accuracy, manufacturing efficiency, and sustainability. Companies that adopt this technology stand to gain a competitive advantage through reduced costs, faster time-to-market, and improved regulatory compliance.  

As innovation continues, digital twins will become an indispensable tool in the future of packaging development.