Brazilian firm Falcare Equipamentos Industriais has reduced operational costs by employing Rockwell Automation’s digital twin technology. The technology, which uses Emulate3D, has allowed Falcare to simulate mechanical behaviour and test complex automation systems before they were built.

According to data from the project, Falcare has seen a 60% improvement in project execution time, enabling quicker customer previews and faster delivery timelines. The company has also reported greater precision and quality due to early validation of equipment behaviour, which has mitigated failures, errors, and costly rework.

Falcare’s previous attempts at using alternative tools were hindered by limitations, including restricted modelling capacity and inadequate mechanical-automation integration. Rockwell Automation’s Emulate3D solved these issues by providing integration between mechanics and controls, delivering a dynamic digital representation of the entire system.

The implementation of Rockwell Automation’s suite of digital simulation and virtual commissioning tools has allowed Falcare to:

• Preview system behaviour before deployment
• Validate control logic and identify physical discrepancies early on
• Streamline commissioning