Automated warehouses deliver high performance, but are technically complex and highly sensitive to change. Testing enhancements, release upgrades or new automation components safely during live operations is extremely challenging, increasing the risk of malfunctions or system downtime.
With the latest major release of PROLAG World, CIM GmbH presents a digital twin for automated warehouses, a practical tool for the safe planning, simulation and optimization of automated warehouse environments. A digital twin is a virtual replica of the real-world automated warehouse that enables realistic simulation of material flows, processes and control logic before changes are implemented in live operations. The result for operators, IT managers and consultants: greater planning reliability and risk reduction.
A digital twin is a 1:1 virtual representation of a real-world warehouse at the software level. Unlike conventional simulations, it is not a static model but an active system: All logistical processes, material flow controls and dependencies are fully mapped, allowing them to be tested, refined and optimized under realistic conditions. In PROLAG World, the digital twin is directly integrated into the warehouse management system and is closely aligned with operational control.
A key advantage of a digital twin is that it safeguards changes before they are applied in the real world. Software updates, release upgrades or adjustments to automated control systems can be fully tested within the digital model – without impacting live operations.
By simulating scenarios and analyzing system behaviour virtually, potential errors are detected early, helping to avoid unplanned downtime and increase long‑term operational reliability. The digital twin also offers a clear advantage when integrating new system components, conveyor technology or additional automated areas. The interaction of all systems can be analyzed and evaluated in advance. As a result, integration risks are reduced, investments become more predictable and projects are streamlined.
Beyond pure project validation, the digital twin in PROLAG World supports the ongoing optimization of your warehouse processes. Bottlenecks in material flow, inefficient strategies or uneven capacity utilization can be analyzed and alternative scenarios tested – all without interrupting with real‑time operations.
The digital twin also opens up new possibilities for training and onboarding. Employees can familiarize themselves with processes, operating procedures and typical malfunctions in a realistic yet risk‑free environment. This increases process reliability and shortens onboarding times.
In conjunction with real‑time data, the digital twin also forms the basis for AI‑supported condition monitoring and predictive maintenance. The solution was developed in collaboration with the Deggendorf Institute of Technology, among others. This makes the digital twin a central component of CIM’s future automation and AI strategy.
With the digital twin for automated warehouses, CIM is expanding PROLAG World with a powerful tool for risk minimization, enhanced process reliability and increased efficiency. Full simulation of complex automation landscapes creates transparency, reduces dependencies during project execution and sustainably enhances operational reliability. At CIM, this vision is being advanced in collaboration with the Deggendorf Institute of Technology as part of the CAIDAN project. Customers are already benefiting from a proven planning and optimization tool that not only supports current automated warehouse operations, but also leaves them optimally prepared for future developments.
