From Equipment Procurement to Technology Evaluation
I recently participated in a webinar with representatives from the packaging industry. The focus was on an open innovation project that addressed the question of how machine concepts can be compared more objectively without having to create extensive specifications every time.
The goal of the project was to develop standardized evaluation criteria that would make different solutions more transparent and comparable. In my opinion, this is a sensible approach, as the procurement of packaging machines is becoming increasingly complex. At the same time, the discussion led me to wonder why we still primarily evaluate machine concepts based on presentations, data sheets, and reference projects.
After all, anyone investing in a new packaging line today is no longer just deciding on a single machine. The decision influences production processes, packaging materials, automation strategies, and often a company’s competitiveness for years to come.
The traditional approach to procurement is increasingly reaching its limits. Suppliers are pursuing different technical approaches that focus on issues such as maximum output, greater flexibility, sustainability, or reduced operating costs. At first glance, each concept seems plausible on its own. The real challenge for companies, however, lies in determining which solution will deliver the best long-term results given their specific circumstances.
In addition, the requirements for packaging systems are currently changing very rapidly. New product variants, shorter product life cycles, and rising customer expectations demand a high degree of flexibility, while sustainability and resource efficiency are becoming increasingly important. Today more than ever, companies must consider which packaging materials can be processed in the future, how quickly format changes can be made, and how regulatory requirements will impact existing production concepts.
This trend is particularly evident in the context of the Packaging and Packaging Waste Regulation (PPWR). The new requirements are increasing the pressure to design packaging that is more material-efficient, more recyclable, and more resource-conserving. As a result, the selection of a packaging technology is increasingly becoming a strategic decision. Investments must not only meet current requirements but also offer sufficient flexibility for future developments.
Against this backdrop, the central question is shifting. It is no longer solely a matter of which machine offers the best performance today; rather, companies must be able to assess now which machine and technology concept will remain economical, sustainable, and flexible in the future as well.
Why Digital Twins Are Changing the Basis for Decision-Making
This is precisely where digital twins offer enormous potential.
To this day, many investment decisions are based on assumptions, empirical data, and manufacturer specifications. While this information is certainly important, it provides only limited insight into how a system will actually perform later on in a specific production environment.
A digital twin opens up a new perspective here. Instead of comparing different machine designs based solely on theoretical performance data, companies can virtually observe their behavior even before making an investment. Material flows, cycle times, energy consumption, format changes, and alternative packaging strategies can be analyzed and compared under realistic conditions.
As a result, the focus shifts away from individual machines and toward a comprehensive production concept.
How does a different level of automation affect productivity? How does output change with new packaging materials? What are the implications for energy consumption, resource use, or changeover times? Which packaging strategy best meets future sustainability requirements?
Questions like these can be answered much more thoroughly with a digital twin than with traditional evaluation methods.
Today, companies no longer have to commit to a specific solution early on, but can first validate different concepts virtually. The evaluation is not based on marketing claims or theoretical metrics, but on the expected behavior during actual production operations.
The Digital Twin as a Platform for Informed Decisions
In my view, that is precisely where the real added value lies. The digital twin is not only becoming a tool for engineering, simulation, or virtual commissioning, but is evolving into a platform for better decision-making.
This makes investments more transparent, identifies risks earlier, and allows for a more objective evaluation of alternative solutions. With the help of the digital twin, companies gain the ability to understand the implications of their decisions long before the first machine is ordered or installed.
Perhaps that is why, in the future, the key question when procuring packaging machines will no longer be, “Which supplier offers the best machine?” but rather, “Which machine concept demonstrably delivers the best results in the digital twin?”
After all, as packaging processes, sustainability requirements, and regulatory guidelines become more complex, the ability to validate decisions before making an investment becomes increasingly important. Digital twins could thus become one of the most important foundations for future investment decisions in the packaging industry.
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