Smart Bakery: A Digital Twin Framework

Melesse T. Y.;Mattia B.;Briatore F.;Mosca M.;Pilloni M. T.;Peer M. S.;Arena S.;Orru P. F.

2025-01-01

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Abstract

The integration of digital twin technology with bakery production systems is a key strategy in modernizing traditional food manufacturing techniques. Digital twins are accurate digital models of physical systems or products, always synchronized with real-time data streams from interlinked physical assets. This paper proposes a conceptual framework for embedding digital twin technology in bakery production environments. The framework is built with four interconnected and complementary elements that include a physical product, simulation model, digital twin system, and stakeholder-supported knowledge base. The four elements as a package create an environment that is dynamic and bidirectional, improving the transparency, responsiveness, and efficiency of bakery value chain operations. The physical product includes Internet of Things (IoT) devices that provide real-time input on process variables like temperature, humidity, and gas concentration. This data is then incorporated into a simulation model that predicts production outcomes under different scenarios, thus enabling proactive decision-making. The digital twin integrates real-time process data with simulation output and uses visualization tools and real-time observational capabilities to support management operations. The knowledge base supported by stakeholders guarantees continuous learning and maintains systemic strategic coherence. The integrated system fosters closed-loop decision-making, predictive maintenance, and improved quality while ensuring sustainability and adaptability. The integration of digital intelligence with human expertise equips artisanal as well as industrial bakeries to manage the digital transformation frontier effectively and benefit from smart manufacturing.