Digital Twins: How We Built a Virtual Copy of a Live Factory

A digital twin is more than a 3D model — it is a living, data-connected replica. Discover our process for a 40,000 sq ft manufacturing site.

When a major FMCG manufacturer asked us to create a digital twin of their 40,000 sq ft production facility, they were not asking for a 3D model. They were asking for a living, breathing replica of their plant — one that would receive live sensor data, flag maintenance anomalies, and let engineers rehearse equipment changes virtually before touching a single bolt.

What Is a True Digital Twin?

A digital twin combines three layers: geometry (the 3D model), data (live sensor streams, BIM metadata, operational parameters), and intelligence (algorithms that predict failure, optimise throughput, and simulate 'what if' scenarios). Without all three layers, you have a 3D model — useful, but not a twin.

Our 5-Phase Process

1. Point-cloud survey — Leica RTC360 laser scanners captured 2 billion points over two days.
2. Model reconstruction — Scan-to-BIM produced an IFC-compliant Revit model of the as-built plant.
3. IoT integration — 240 OPC-UA sensor feeds were mapped into the Unreal Engine data layer.
4. Dashboard development — A web-based control room visualises real-time temperature, throughput, and alert states.
5. Simulation environment — Engineers can freeze time, rewind to any historical state, and simulate maintenance windows.

"We identified a bearing failure 11 days before it would have caused a line shutdown. The digital twin paid for itself in the first three months." — Plant Manager