Rockwell Automation Digital Twin Cuts Falcare Project Time 60%, Reduces Costs
Rockwell Automation’s digital twin tech reduced Brazil-based Falcare’s project execution time by 60% and cut operational costs through early simulation and validation of robot and conveyor speeds. The implementation improved energy efficiency, operational predictability, waste reduction and precision while accelerating customer previews and delivery timelines.
1. Implementation of Emulate3D Digital Twin
Rockwell Automation deployed its Emulate3D™ platform to create a full virtual commissioning environment for Falcare’s automation systems in Sao Caetano do Sul. The digital twin simulated robot and conveyor behavior before physical assembly, validating control logic and identifying design discrepancies. Integration of mechanical and control data enabled seamless early-stage testing without costly prototypes.
2. Quantifiable Efficiency and Cost Outcomes
Falcare achieved a 60% reduction in project execution time and significant operational cost savings by eliminating field rework and shortening sales cycles. The digital validation process improved system precision, cut energy consumption and reduced material waste. Early customer previews and post–sales support were enhanced through accurate digital modeling of machine performance.
3. Implications for Rockwell’s Market Position
This success with a major Brazil-based equipment provider demonstrates Rockwell’s capability to drive sustainable intralogistics solutions worldwide. The case study may accelerate adoption of virtual commissioning across automotive, food and beverage, and logistics sectors. Strong client results could support revenue growth and reinforce Rockwell’s leadership in industrial digital transformation.