In the production of detergent capsules, thin sheets of water-soluble film are heated, shaped, filled with detergents, moisturized and then sealed. Variations in the base material, and variations in applied temperature, humidity and mechanical forces can all influence the quality of the finished product and the speed at which it can be produced.

To achieve more predictable results in the high-speed production processes, extra monitoring is desired on the various factors that are directly influencing the quality of the finished product and the performance of the machine.

Developments in sensor technologies, computing power and connectivity have, over the last decade, revolutionized the production environment now known as Industry 4.0.

The philosophy behind Industry 4.0 can also be applied to the production of detergent capsules. The goal is to have real-time data from multiple different sensors, throughout the production process. This data is stored, analyzed and then used in real-time to optimize the production process.

To achieve this goal, TRICAS has joined her parent company Tembo to develop a digital twin in which various sensors are communicating with a database which in turn is visualized in a digital model of the desired product.

This way we aim to improve the efficiency of the production process, the stability of product quality, the reduction of waste and, by predictive maintenance, the lifespan and efficiency of the production machinery. This is one of the steps on the way to realizing the future goal of a fully automated ‘dark factory’.

Do you want to know how TRICAS can help you in realizing a digital twin? Check: and get in touch.