Closed-Loop Digital Twin for Energy-Efficient Scheduling in Food Manufacturing Systems

Food manufacturing faces challenges in balancing efficiency, energy use, and quality. This paper presents a Hybrid Digital Twin Architecture (HDTA). It combines simulation, constraint programming, and Industrial IoT into a closed-loop system. The architecture has three layers: simulation for planning, optimization for scheduling, and an edge layer for control. We validated this using a bakery model with 10 products. The results show a 24.4% reduction in production time and 23% energy savings. Simulation results show complete elimination of quality time-window violations (0.0% vs. 13.3% baseline, p < 0.001). The system achieved a 2.4-month return on investment. This work demonstrates how combining these technologies can improve process industries.