Sensors, AI, Action! Digital Twins Redefine the Industrial Sector

In a world where every second matters, technology redefines how industries operate, plan, and thrive. Digital twins, tools that once seemed like science fiction, are taking manufacturing, logistics, construction, and sustainability to unprecedented levels. These virtual replicas of objects and spaces can predict problems, transform companies' decisions, optimize resources, and mitigate risks.

With this ability to understand and improve what already exists, key questions arise: How does the world change when we stop reacting and start anticipating? What does innovation mean when even the future can be modeled?

Salvio Folch leads Grupo Jumex. This nectar and juice company uses digital twins in Mexico. Photo: SiiLA.

By: SiiLA News

01/16/2025

In Mexico's northern region and the Bajío, where steel is transformed into infrastructure and fruit nectar is bottled with precision, giants like Prolamsa and Grupo Jumex occupy at least 160,000 square meters of industrial space, according to SiiLA. Inside some of their facilities, among packaging lines and laminators, something extraordinary is happening. Like many others in Mexico, these companies use digital twins to monitor, optimize, and transform their operations in real-time.

A digital twin is a virtual model of something, whether physical or not: an industrial facility, a machine, or even an entire system. This model works by collecting sensor data, which, through advanced software, is processed into actionable insights to optimize operations. How does it work? Imagine an intelligent mirror that reflects what is happening and detects problems before they occur, suggests solutions, and simulates improvements before applying them. From adjusting the pace of a production line to planning more efficient logistics routes, the digital twin is the brain behind faster, more precise, and more profitable operations.

This technology, which seems straight out of a science fiction novel, is transforming industries worldwide. According to MarketsandMarkets, a research firm specializing in market trends and technology, the global digital twin market will grow at a compound annual rate of 61.3% between 2023 and 2028, driven by key industries such as construction, manufacturing, and logistics. Meanwhile, IT consultancy Gartner predicts that by 2025, 25% of multinational companies will use this tool.

In Mexico, the impact of digital twins is already evident. According to Wired in Spanish, the artificial intelligence company Allie, which collaborates with giants such as Grupo Bafar, Grupo Jumex, Iusa, and Prolamsa, reported that its clients have increased operational efficiency by 8% to 17% and reduced waste by up to 20%.

For an industrial market that has over 7,000 active properties across more than 100 million square meters and generates around 32% of Mexico's GDP, according to SiiLA and INEGI, widespread improvements in operational efficiency like those reported by Allie could translate to a potential GDP boost of nearly 1 trillion pesos (approximately USD 56.8 billion).

Digital twins are used to optimize production processes. Photo: BigStock.

Yet, the benefits of digital twins go beyond the numbers.

In manufacturing, these virtual replicas have revolutionized plant operations by anticipating machinery failures, reducing downtime, and extending equipment lifespans. For instance, operators can receive early alerts about potential issues through predictive analysis of historical data and current conditions, preventing costly interruptions and optimizing production. In terms of sustainability, this technology has helped reduce energy consumption by automatically adjusting lighting and climate control systems based on environmental conditions, achieving significant savings and meeting environmental goals.

In logistics, the impact of digital twins is equally transformative. Global companies like DHL have adopted this technology to optimize delivery routes, manage inventories, and reduce operational times. According to reports, its implementation has improved delivery times by 25% and increased operational efficiency by 30%, reducing costs and fuel consumption. Beyond process improvements, these tools also create safer environments for workers and ensure more accessible and sustainable products for consumers.

In the context of nearshoring growth, adopting digital twins could position Mexico as a key destination for global supply chains, offering advanced and competitive industrial infrastructure.

However, while these cases highlight the immediate benefits of digital twins and their potential to redefine industries, their implementation comes with challenges. One of the main hurdles is the initial investment required to develop and integrate the technology, including advanced sensors, data analysis platforms, and trained personnel. Additionally, ensuring cybersecurity remains a constant concern, as managing large volumes of sensitive data could make these infrastructures attractive targets for hackers.

Digital twins do not simply anticipate failures or optimize routes; they anticipate a future where industries no longer react to problems but prevent them from occurring altogether. This marks the beginning of an era where foresight replaces correction, and digital intelligence amplifies decision-making. The real challenge will not be implementing this technology but imagining how far we can take it.

To learn more about the impact of digital twins and other advances in the industrial sector, visit SiiLA REsource or contact us at contacto@siila.com.mx.

Latam

Mexico

National

Industrial

Market Analytics

Market Trends

ABOUT SiiLA

Founded in 2015, SiiLA is the industry leading REsource for comprehensive commercial real estate market insights, news and events across Latin America. The SiiLA suite of innovative products drive greater accuracy, efficiency, and strategic advantages for top players in the commercial real estate industry.