Virtual commissioning

04/27/2026

A new approach to commissioning: faster, safer, more predictable

Virtual commissioning – a new standard in project management: In the project for Sofidel in Duluth, Minnesota, BT-Systems is, for the first time, relying entirely on virtual commissioning based on a digital twin of the entire plant. The aim is to move development, testing and commissioning processes into a digital environment at an early stage, thereby significantly reducing the effort, risks and costs in the later phases of the project. Virtual commissioning fundamentally changes the traditional process: Control software, material flow, interfaces and process logic are tested before the actual system is installed. This is now standard practice for most PLC commissioning projects. This means that errors can be identified and rectified at a stage when corrections can still be made easily, quickly and cost-effectively.

Test early, reap the benefits later
In conventional projects, commissioning usually only begins once the mechanical installation has been completed. Software errors, process adjustments or interface issues are then resolved on site under considerable time pressure. This results in additional work, rising costs and an increased risk of delays. With virtual commissioning, this critical stage is brought forward to the early stages of the project. All processes are simulated realistically using a digital twin of the plant: from the control logic and material flow to the interaction between all the systems involved. Adjustments are made where they require the least effort – in the virtual model. In practical terms, this results in shorter lead times, more stable processes and significantly less rework.

Measurable efficiency gains
The benefits are evident not only in terms of quality, but also in concrete figures. Experience gained from industrial projects shows that the actual time taken to commission software can be significantly reduced. At the same time, the amount of rework required is reduced significantly. In addition, there are lower travel and staff costs, as well as faster production approval. Operators benefit from higher plant availability, particularly during the start-up phase. Processes have already been tested, procedures are well-established, and disruptions have been reduced. The plant reaches the target output range more quickly. Another aspect is safety: Critical scenarios, borderline cases or fault conditions can be simulated safely. Complex tests involving heavy or bulky products can be simulated virtually – without any risk to people or machinery.

Plug-and-play as a logical addition
Virtual commissioning realises its full potential when combined with modular prefabrication in all projects where this is feasible. Key assemblies are fully wired, tested and pre-configured at the factory. On-site installation follows a clearly structured plug-and-play principle. As the functions and processes have already been validated virtually, commissioning is limited to the targeted integration of the modules. This reduces complexity, shortens assembly times and improves the reproducibility of project workflows. It offers a clear advantage for operators: reliable scheduling, a rapid ramp-up and a smooth handover of the plant.

Transparency in the early stages of a project
A digital twin not only offers technical benefits, but also improves collaboration with the customer. Material flows, layouts and operating concepts can be visualised realistically at an early stage. Processes become transparent, options can be assessed in a targeted manner, and workflows can be optimised collaboratively. Changes are made on the basis of a shared understanding – long before they would need to be implemented on site, which would be both time-consuming and costly. This provides planning certainty, reduces the need for coordination and improves the quality of the end solution.

In-house interdisciplinary expertise
The virtual commissioning process at BT-Systems was developed by an in-house team of experts specialising in automation, software development, simulation and plant engineering. This enables the company to bring together key expertise across the entire engineering chain under one roof. When combined with our digital, standardised data pool, project phases can be decoupled in a targeted manner. PLC programming can be tested virtually even before the detailed mechanical and electrical designs have been finalised. This parallel approach shortens project lead times, enhances quality and improves the manageability of complex projects, such as “in-house training courses”.

Market relevance
Virtual commissioning is increasingly becoming an integral part of modern automation projects. Customers are demanding virtual factory acceptance tests, shorter project durations and greater planning certainty. Digital testing methods are increasingly being defined as a mandatory part of projects. By consistently expanding these capabilities, BT-Systems is strengthening its position in the market. We don't see virtual commissioning merely as a technical tool, but as an integral part of a forward-looking project methodology, such as in-house training courses.

Conclusion
Virtual commissioning moves key project phases into the digital realm – offering clear benefits in terms of efficiency, quality and planning reliability. The Sofidel project demonstrates how complex plant projects can be implemented more reliably, quickly and cost-effectively through early-stage simulation and testing. The project is currently in the implementation phase. Installation and step-by-step commissioning are proceeding according to plan.

Benefits:

Planning certainty
Faster processing
Optimisations even before launch
Early fault detection
Shorter start-up time
Training sessions can be arranged in advance
Greater availability
Greater security
Improved cooperation
Cost reduction

INTERVIEW

Nicolas Markus: Head of the PLC Programming, Commissioning & 24/7 Service Division

What exactly does the digital twin offer?
We can test the entire system before it is actually installed. This reduces risks, shortens the commissioning process and noticeably improves quality. Test runs, which tie up a lot of staff on the actual site and often have to be carried out with heavy, bulky goods, can be simulated virtually with just a few clicks.

What is the biggest benefit for the customer?
Greater availability during the significantly shorter system ramp-up phase, as well as the opportunity to evaluate the system, its operation and the customer’s systems at an early stage and without risk – a genuine win-win situation.

Is this the future of commissioning?
We are fully convinced that it is. VIBN is THE future tool for the entire automation industry.

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