Design, Test & Optimize Before You Build
Emulate your entire automation system in a high-fidelity digital twin — validate control logic, reduce commissioning time, and deploy with confidence.
3D Emulation Environment
Emulate Every Aspect of Your System
From control logic validation to operator training, digital twin emulation transforms how you design, test, and deploy automation.
Virtual Commissioning
Test and validate your control logic against a virtual replica of your production line — before any physical equipment is installed.
Performance Optimization
Identify bottlenecks and optimize throughput using physics-based simulation, driving higher OEE from day one.
Risk-Free Testing
Simulate edge cases, failure modes, and process changes in a safe digital environment — no downtime, no damage.
Training & Scenario Simulation
Train operators on realistic digital replicas and run what-if scenarios to prepare for any production challenge.
Three Steps to Digital Confidence
A streamlined workflow from virtual design to real-world deployment.
STEP 01
Model Your System
Import CAD layouts and define your production environment with drag-and-drop modeling tools. Build an accurate digital replica of conveyors, robots, and stations.
STEP 02
Emulate Control Logic
Connect your PLC programs to the virtual model. Run real controller code against the digital twin and validate behavior in real time.
STEP 03
Deploy with Confidence
Once verified in simulation, take your validated programs straight to the plant floor. Reduce commissioning time and eliminate costly surprises.
Built for Your Industry
Digital twin emulation delivers measurable value across manufacturing and logistics verticals.
Automotive Manufacturing
- Validate robotic welding and assembly line sequences virtually
- Cut commissioning time for new vehicle programs
- Simulate model changeovers risk-free
Consumer Goods & Packaging
- Optimize high-speed packaging line throughput
- Test recipe changeovers in simulation
- Train operators before line startup
Warehousing & Intralogistics
- Emulate conveyor sortation and ASRS systems
- Validate WCS/WES integration before go-live
- Stress-test peak-volume scenarios digitally
Process Manufacturing
- Simulate batch control and continuous process flows
- Verify safety interlocks in a risk-free environment
- Optimize energy consumption through what-if analysis
Technical Highlights
Enterprise-grade emulation built on industrial standards.
FactoryTalk DesignSuite Integration
Seamless connectivity with the Rockwell FactoryTalk ecosystem for unified engineering workflows.
PLC & Controller Emulation
Run real controller firmware in a virtual environment — test ladder logic, structured text, and function blocks.
Physics-Based Simulation
Accurate kinematics, dynamics, and material flow modeling for true-to-life system behavior.
OT/IT Connectivity
Bridge operational technology and IT systems with standard protocols — OPC UA, EtherNet/IP, and more.
For Rockwell users: Tightly aligned with the FactoryTalk ecosystem — leverage your existing Studio 5000 projects, Logix controllers, and engineering data without conversion overhead.
Results That Speak
30%
Fewer onsite changes
50%
Time saved in testing
40%
Faster commissioning
3×
More scenarios validated
"Digital twin emulation fundamentally changed how we commission new lines. We catch issues weeks earlier and our teams arrive on-site fully prepared."
Rapid Deployment for Emulate3D
From zero to a production-ready digital twin in 15 days — integrated, scalable, and ready for analytics.
A 15-day structured engagement that enables OEMs and manufacturers to stand up a production-ready digital twin environment using Emulate3D — accelerating simulation, virtual commissioning, and analytics.
Not Training · Deployment + Best Practices + Usable AssetsThe Problem We Solve
Most organizations struggle to extract real value from digital twin investments.
No standardized digital twin framework
Slow onboarding of Emulate3D
Lack of integration with PLC / controls
No reusable modeling libraries
Simulation ≠ business value (no linkage to operations)
High cost, low adoption, delayed ROI
Outcome with ITHENA: A working digital twin that earns its keep — fast.
15-Day Delivery Plan
A phased, outcome-driven engagement from foundation to handover.
Week 01 · Foundation
Architecture & Environment Setup
- Use-case definition (line / machine / process)
- Data + CAD + PLC inputs assessment
- Environment setup (Emulate3D workspace)
- Base model creation (layout, assets, flows)
- Integration strategy (PLC / tags / APIs)
Week 02 · Build
Model + Controls Integration
- Build simulation models (conveyors, robots, machines)
- Connect to PLC logic / emulation
- Define material flow, system logic, event triggers
- Introduce fault simulation
- Scenario testing & validation
Week 03 · Optimize
Optimization & Handover
- Throughput & bottleneck analysis
- What-if simulations
- Visualization dashboards
- Operator scenarios (training use cases)
- Final documentation + knowledge transfer
What You Get
Concrete, reusable assets delivered against both engineering and business outcomes.
Technical Deliverables
- Fully functional Emulate3D model
- PLC-connected simulation environment
- Simulation scenarios (normal + fault cases)
- Performance outputs: throughput, utilization, bottlenecks
Business Deliverables
- Digital twin deployment blueprint
- Reusable component libraries
- Scaling roadmap (multi-line / plant level)
- ROI model (commissioning time saved)
Best Practices Embedded
ITHENA IP that accelerates time-to-value and ensures long-term scalability.
Modeling Standards
- Modular, reusable assets (conveyors, stations, robots)
- CAD-to-simulation acceleration
- Naming + tagging standards
Controls Integration
- PLC tag mapping frameworks
- Virtual commissioning templates
- Fault injection library
Data + Analytics (AETHER Ready)
- Simulation data → analytics pipelines
- Hooks for OEE / OOE
- Predictive insights & scenario optimization
Value to the Customer
Quantifiable impact across every stage of the automation lifecycle.
Why ITHENA
We don't just build a model — we create a Digital Twin + Intelligence Layer.
Others
Focus on simulation tools.
ITHENA
Combines Simulation + Data + AI + Applications into one intelligence layer.
→ A digital twin that doesn't just run — it learns, informs, and scales.
Commercial Model
Fixed Fee · 15-Day Accelerator
Includes consulting, implementation, model build & integration, documentation and full handover.
Optional Add-Ons
- Multi-line scaling
- Enterprise digital twin (Factory Test)
- Integration with AETHER platform
Expansion Path
Post-Engagement Roadmap
Your 15-day deployment is a launchpad. From there, the digital twin scales with you.
- Scale to full plant digital twin
- Integrate real-time IoT data
- AETHER-powered optimization engines
- Predictive maintenance & decision intelligence
Ideal Customers
OEMs (Packaging, Material Handling, Automotive), System Integrators, and manufacturers with complex lines, heavy automation investment, or frequent commissioning cycles.
From zero to a production-ready digital twin in 15 days — integrated, scalable, and ready for analytics.Start Your 15-Day Deployment