Digital Production for Real-World Products
The TechMAS extruder digital twin, jointly developed by Partner-M and ITMO University, could improve the efficiency of plant-based raw material processing.
Automation is a global trend in food manufacturing, but digitizing process monitoring, control and production upgrades is just as important. Many manufacturers, for example, use robots and build dedicated robotic production lines. To get more out of these systems, however, they need digital twins of their production operations. Virtual models make it possible to diagnose, simulate and forecast process performance without putting actual plants and factories at risk. They can help manufacturers increase output and cut costs. Building these digital twins is a complex undertaking that Russian researchers and industrial companies are tackling together.
The Extruder Digital Twin
At the 3rd International BIOPROM Forum, “Industry and Technologies for People,” the Strong Artificial Intelligence in Industry Research Center at ITMO University and Partner-M presented the TechMAS extruder digital twin to industry experts. The project marks an important step in the development of Russia’s high-tech food manufacturing sector.
The first extruders appeared in the United States in the 1960s, revolutionizing the production of ready-to-eat foods. This type of equipment combines high temperatures, pressure and mechanical forces to turn plant-based raw materials into a wide range of products. The machine forces plasticized material through a forming die. A processing cycle takes between five seconds and two minutes, making the technology highly efficient. Beginning in the 1970s, the Kuibyshev Aerodrome Equipment Plant in the Soviet Union also manufactured extruders for processing grain and legumes.
Improving Production Efficiency
The TechMAS digital twin for high-moisture extrusion was developed using data from operating equipment and 3D modeling. “Together with Partner-M, we are using a real industrial BCTH-125 extruder, including its geometry, process parameters and operating data, to build and validate a digital model,” said Ilya Revin, a senior research scientist at ITMO University who holds a Ph.D. in engineering.
The new platform is expected to help accelerate the development of new production cycles for the physical extruder. The digital twin allows engineers to evaluate different temperatures, pressures and other operating parameters in a virtual environment. Manufacturers will be able to rule out unsuitable operating conditions before conducting trials on industrial equipment.
This is particularly important when developing new food ingredients, because digital testing does not require production capacity to be taken offline or used for physical trials. The main goal is to unlock the potential of raw materials through advanced processing. Over time, food manufacturers could improve their profitability.
“Our work is advancing on two fronts: deep processing and the digitalization of that processing stage. This will not only speed up R&D but also reduce losses,” said Artem Ponomarev, CEO of Partner-M.
Predicting Food Product Properties
Further development of the TechMAS extruder digital twin will make it possible not only to automate the selection of process parameters but also to predict product characteristics. Manufacturers will be able to assess how physical processes inside the machine affect the properties of the resulting material. This capability could be particularly valuable when developing foods with specific textures and other characteristics that are increasingly popular among health-conscious consumers.
“We have essentially learned how to produce everything, and now we need to move to the next level: functional and personalized nutrition. For the industry, this marks a new stage of investment and development,” said Oksana Lut, Russia’s Minister of Agriculture.
Digitalization is essential if Russia’s food industry is to compete effectively in global food markets. According to forecasts by consulting firm Towards FnB, the global AI market for food manufacturing will grow nearly tenfold over the next decade, from $9.51 billion in 2025 to $90.84 billion by 2034. Automation and machine learning are expected to become increasingly integrated into manufacturing processes.
Exports of products made through the deep processing of plant-based raw materials are already one of the higher-margin segments of Russia’s agricultural industry. Partner-M sells its products in Europe, Asia, Latin America and the Commonwealth of Independent States (CIS). The new platform could help the company increase output, improve product quality and expand exports.
