How can Digital Twins support Manufacturers on the path to Net-Zero?

What are Digital Twins and
how can they support Food &
Drink Manufacturers on the
path to Net-Zero?
Online Demo
Adam Goves, Sector Lead – Manufacturing and Infrastructure
Laurie McKelvie - ICL Senior Operations Consultant

Adam Goves, Sector Lead – Manufacturing & Industry, IES
Adam has been working in decarbonisation, energy use reduction, energy security and renewable energy generation
for over 20 years now. He has extensive experience in managing client relationships and delivering mutually
beneficial contracts focused on engaging with the journey towards Net Zero. In his current role as Sector Lead for
Manufacturing & Industry at IES, he brings a wide-ranging understanding of the renewable energy market and the
opportunities that technologies bring to both new and existing buildings, as well as extensive experience in energy
assessment and analysis.
Laurie McKelvie, ICL Senior Operations Consultant, IES
Laurie has worked within the Building Services Industry for over 10 years and has amassed a wealth of practical, project
and academic experience during this time. With over eight years of Building Services Consultancy experience, Laurie has
developed a wide range of expertise focused on sustainability-lead design solutions and has led large-scale projects and
teams through the entire construction process.
Laurie has also gained valuable site experience working within a site facilities team developing and implementing practical
energy management and plant replacement strategies for the site. He has also developed a high level of competency in
dynamic energy modelling which has complemented his understanding of built environment energy and carbon reduction
strategies.
Your Presenters Today

>1,000,000
Buildings
About IES
Home to the largest building physics analytics team in the world
75,000+
Projects per year
40
Power stations
prevented
29
Years of building
analysis
Apache
World renowned
simulation engine

www.iesve.com
What IS a Digital Twin?
 A virtual replica of a building and processes
which gathers real data and uses physics-based
simulations to respond and behave in the same
way as its real-world counterpart
 Allows you to analyse how your buildings and
associated infrastructure are performing now,
gain insights into how they should be
performing and explore different scenarios to
understand the impacts of future changes
 Provides investment-grade decision support
information to improve asset performance,
influence future process and building designs
and retrofit to reduce investment risks

Audience Poll
How far along in your decarbonisation &
Net Zero journey do you think you are?
1. Not started yet 10. Fully optimised

ICL Digital Twins help you identify and deliver:
Energy use reductions
Energy cost reductions
ESG monitoring and reporting
Waste heat management reductions
Carbon reductions and Net-Zero road mapping
Manufacturing process efficiency improvements
Building efficiency improvements
Digital Twins for the
Food & Drink Industry
Increase production efficiency, reduce energy
use, lower energy costs & divest from fossil
fuels with Net Zero road mapping and ESG
reporting

www.iesve.com
Key Issue: Solution:
Reference: Dr Michael Oates, IES Ltd, PhD Thesis - https://www.dora.dmu.ac.uk/handle/2086/2388/browse?value=Oates%2C+Michael&type=author
Holistic Approach to Production Modelling

www.iesve.com
Our Digital Twin Solution
 The IES Digital Twin is a detailed, calibrated, evolving
digital representation of your buildings, processes,
infrastructure, energy usage and waste generation
 It’s a Lifetime Digital Asset for monitoring, energy cost risk
reduction, ESG reporting, carbon reduction and net-zero
investment road-mapping

Our Approach
Simplified data management, organisation and visualisation
 Access entire operational data for complex processes in one
place from anywhere
Digital Twin of processes and buildings
 Virtual copy of facility to analyse and understand future
operations without physically changing anything
Simulation & analysis of changes to process layouts, behaviours,
& technologies
 Reduce energy consumption and improve energy efficiency
of operations and buildings
 Analyse and understand impact and benefit of potential
local energy production
 Simulate the potential for waste heat recovery and reuse
www.iesve.com

www.iesve.com
 Long on data; short on insights - users have multiple lines, data
sources and systems, but no unified access to production data
 Import data from variety of sources - BMS, sensors on
equipment, IoT sensors, virtual sensors, existing databases,
utility bills
 Manual or automated data uploads
 AI & machine learning – fills gaps in data and checks sensors are
within range
 Data visualised through online dashboards - view production
data securely anywhere in the world
Simplified Data Management,
Organisation & Visualistaion

www.iesve.com
 Digital Twins can be used to model numerous scenarios to improve
the effective and efficient running of manufacturing and packaging
processes
 Optimal scenarios for both technical and economic requirements
can be simulated, chosen and actioned
 Simulations and analysis may include:
 Changes to operating profiles to reduce energy consumption
 Impact and benefit of potential local energy production for use
in the facility instead of supply from the grid
 Simulate the potential for waste heat recovery and reuse
Simulate & Analyse Changes to
Equipment Operation & Technologies

How We Cut Energy Costs
www.iesve.com
Data Gathering
Together, we will identify and gather energy consumption and
metering data, system performance data, manufacturing
process data, building performance and building use data
including occupancy profiles.
Accurate Modelling & Identification of Energy Savings
We put the available data sets through our world renowned
Digital Twinning software to provide insights into energy
wastage. We then identify key energy saving measures with
accurate forecasting of potential savings and payback periods.
Step towards Net-Zero
We can further develop the Digital Twin to take you to the next stage
and test scenarios that moves you to net-zero & energy self sufficiency.
1
3
2

Direct Engagement and Partnering Options
www.iesve.com
 IES Consulting can engage directly with your organisation and your energy and sustainability teams
 IES Consulting can engage with your existing energy and sustainability partner organisations to
enhance their offerings to you, working in collaboration to deliver improved results.
Example partner companies:

www.iesve.com
Scope 3 - IES for supporting farming futures:
Environmental resilience – Innovate UK
1. Funding call from the Department for Environment, Food & Rural Affairs (Defra) – July 19th deadline
2. Solutions to “resolve key issues affecting the sector, where sustainable and resilient farming solutions can mitigate
climate challenges and increase productivity”
3. Projects must seek to significantly improve:
a) productivity
b) sustainability and environmental impact of farming
c) progression towards net zero emissions
d) longer term resilience
e) food security
4. Proposals must
1. demonstrate environmental benefits and societal impact
2. ensure your solutions are closely aligned with industry priorities to deliver business-orientated and
transformative opportunities
3. consider how it will encourage dissemination and knowledge exchange to the wider sector
Funding support of
between 50% and
70% available

www.iesve.com
• Create model of factory and processes
Example: Food Manufacturer, Spain
• Import data & create profile of energy
demand from different processes and
systems
• Create electricity cost tariff planner
for financial year
IES was asked to perform the following:
• Run analysis for possible load shifting
• Change times equipment is used to move
energy consumption to cheaper hours
• Results: Immediate 6 month savings =
€18,111: Initial ROI under 1 Year

www.iesve.com
Import data & create
profile of energy demand
from different processes
and systems: Create electricity cost tariff planner for whole year Run analysis for possible load shifting

www.iesve.com
Immediate Action
Identified:
Modify equipment run times to
move energy consumption to
cheaper hours/renewable source
Immediate Results:
Energy savings made
(6 months) = €18,111
(1 year) = €36,222
Renewable energy generation
& detailed Net Zero road
mapping opportunities
analysed & identified

Your Return on Investment
www.iesve.com
Immediate Energy Efficiency Gains
The process of gathering and collating your built environment and
manufacturing process data itself will identify immediate energy
and process efficiency gains hidden within. These simple gains
alone often cover the capital cost of your investment
“What If?” Scenario Planning and Strategic Views
Once the data is collated and your virtual Digital Twin is built,
you can run unlimited engineering, control or behavioural
scenarios through the model without any risk to the business.
You will identify significant and strategic deliverable
improvements with fact based analysis.
A Quantifiable, Measurable and Defined Net Zero Road Map
You will have the tools at hand to plan ahead towards your Net
Zero targets. Your road map will be fact based, reportable,
costed, measurable and robust.
1
3
2
Immediate energy
and cost savings
of up to 20%
Identify and
deliver continued
additional cost
and carbon savings
along your Net
Zero Road Map

Audience Poll
Which barrier is most difficult to
overcome in your decarbonisation and
Net-Zero journey?
1. Cost/Return on Investment
2. Internal/C-Suite/colleague buy in
3. External/third party support
4. Supply chain
5. Other priorities

Net Zero Road-Mapping Example
Palm Springs Campus
Palm Springs Campus.mp4

How can Digital Twins support Manufacturers on the path to Net-Zero?

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