Digital Twin of an oxidation plant

Company name

Gaser Srl

project title

Digital Twin of an oxidation plant to support scheduling and process optimization

dimension and location

Medium enterprise - Rozzano (MI)

technologies

Digital twin

Gaser Srl is a leading company in the metal surface treatment industry for over 50 years, offering innovative solutions to enhance the corrosion resistance, wear resistance, and aesthetics of metal components. 

The problem

The company has embarked on a digitalization journey, but currently, job scheduling and management rely on the experience of managers using tools that do not easily identify inefficiencies and bottlenecks. The current solutions are manual and tested directly in the real environment, with risks of resource waste and failures. 

The solution

The project involved creating a Digital Twin of an oxidation plant. This digital model will allow the plant’s operations to be simulated, optimizing job scheduling, monitoring efficiency, and reducing downtime and waste. Additionally, it will enable predictive analysis of failures and maintenance, reducing the risk of unplanned plant shutdowns. 

Technologies 
The project utilized Digital Twin technology, sensors for data collection, analysis platforms, and advanced scheduling algorithms. Production layout simulations can thus be performed in a virtual environment before being implemented in the real plant. 

Desired Impacts

Implementing the Digital Twin will improve production efficiency by reducing time, resource, and energy waste. Equipment and raw material usage will be optimized, ensuring on-time deliveries and improving product quality. 

Benefits for the company

The project will enhance the company’s competitiveness by reducing inefficiencies, controlling costs, and increasing production capacity. Predictive simulation will help prevent machine stoppages and breakdowns, positively impacting process quality and sustainability. 

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