Understanding Digital Twins and Their Role in Pharma 4.0
Author: Jinhong (Andrew) Kim, Director, Industrial South Korea, AtkinsRéalis
Introduction to Digital Twins
The demand for advanced technology in the pharmaceutical industry is driven by the need to enhance cost efficiency while maintaining high safety standards in new medical developments. According to a recent industry report, the global market for Digital Twins (virtual models of real-world physical objects or processes in real-time) in pharmaceutical manufacturing is estimated to reach $374 million in 2024, growing at a compound annual growth rate (CAGR) of 31.3% from 2024 to 2034.
Digital Twins are advanced virtual models that mimic physical objects, systems, or processes in real-time. Utilizing data from sensors, IoT devices, and other sources, Digital Twins simulate the behavior, operation, and condition of their real-world counterparts. This technology has garnered worldwide attention, with growth and innovation expected to continue beyond 2024. Advancements in AI, IoT, and data analytics are driving the rapid adoption of Digital Twins across various industries.

Pharma 4.0: Digital Transformation in the Pharmaceutical Industry
Pharma 4.0 represents the digital evolution of the pharmaceutical industry, incorporating advanced technologies and concepts from Industry 4.0 (Fourth Industrial Revolution), including cyber-physical systems, IoT, and cloud computing. This transformative approach aims to revolutionize pharmaceutical manufacturing and processes by integrating automation, data analytics, IoT, and AI. The primary goals of Pharma 4.0 are to enhance efficiency, quality, and flexibility in pharmaceutical production, ensure regulatory compliance, and quickly respond to market demands.
Pharma 4.0 emphasizes the digitalization of production and distribution processes. By integrating digital technology from the early stages of new construction projects, more realistic and forward-looking solutions can be provided. This proactive approach ensures a robust digital foundation is already established when the project advances to production and distribution phases, providing crucial data and allowing for continuous digital integration.
Available Digital Solutions
- Process Optimization: Methods to improve efficiency in production and operational processes.
- Real-Time Process Monitoring: Technology for real-time monitoring of actual processes to enable immediate responses.
- Digital Maintenance: Maintenance of equipment and systems using digital technology.
- Predictive Maintenance: Techniques for minimizing downtime by predicting failures and performing maintenance in advance.
- Operational Efficiency Enhancement: Improving overall operational efficiency.
- Integrated Solutions: Methods to improve efficiency by integrating multiple systems and processes into one.

AtkinsRéalis provides engineering service consulting. By adopting 3D modeling technology at the initial stage of process design, digitalization can be integrated into new projects. The main features of this approach include:
- Robust Review Capabilities: Enhanced review capacity for improved precision and efficiency in design assessment.
- Seamless Access to Material Data: Facilitates easy access to relevant material data, streamlining design and procurement processes.
- Export to ISO Drawings, Plans, and BOM: Allows design data to be exported to standardized ISO (International Organization for Standardization) drawings, project plans, and Bill of Materials (BOM).
- Integration of Drawings, Data, and Information: Ensures consistent management by integrating all design-related drawings and data.
- Change Management – Track & Trace: Comprehensive tracking and management of all changes throughout the project lifecycle.
- High Efficiency and Security: Enhanced efficiency through built-in data libraries and strong security features.
Benefits of Digitalization in Pharmaceutical Projects
Current bio and pharmaceutical projects in Asia increasingly utilize Smart Plant 3D, E3D, and BIM (Building Information Modeling). These powerful tools enable visualization across disciplines, improve the feasibility of route planning, and are integrated for ISO drawing extraction and quantity calculation. Compared to traditional 2D and simple 3D modeling, these methods provide more accurate forecasts and can be applied in various ways for system management in future operational states.
The advantages of digitalization include:
- Regulatory and Legal Compliance: Ensures adherence to legal and regulatory standards.
- Integrated Project Delivery (IPD): Supports various project delivery methods, including Integrated Project Delivery.
- Scalability and Flexibility: Maintains adaptability throughout the entire project lifecycle.
- Enhanced Interdisciplinary Collaboration: Improves collaboration and efficiency across different fields.
- Schedule and Cost Savings: Achieves significant time and cost savings during the construction phase.
Additionally, integrating BIM enables comprehensive modeling of the entire structure. Combined with additional data like schedules and specifications, this model provides a robust solution applicable to maintenance and project management throughout the production stage.
Adoption of Advanced Digitalization
Adopting a more advanced approach to digitalization requires strategic planning, collaboration, and execution compared to traditional methods. Leveraging case studies and expert insights helps ensure project success and efficient outcomes. Collaborating with experts who understand diverse requirements and provide flexible scalability is crucial for developing a comprehensive business plan.
For more on the end-to-end expertise AtkinsRéalis offers in the pharmaceutical sector and how it can support future projects, please visit here.
Notice: Learn More in the Upcoming Seminar
AtkinsRéalis will present at the JASIS 2024 topic seminar, “Digital Transformation in the Biopharmaceutical Industry,” with simultaneous interpretation in English and Japanese.
The seminar will introduce an overview of digital transformation in the biopharmaceutical industry and practical approaches to 3D modeling in greenfield and brownfield projects.
Program | Description |
---|---|
Introduction | Overview and purpose of the seminar |
Digitalization | Importance of digitalization and industry status |
Pharma 4.0 | Latest trends and technology in the pharmaceutical industry |
BIM, Digital Twins, Smart Factory | Introduction of cutting-edge technologies and applications |
Case Study 1 | Greenfield project using VR |
Case Study 2 | Brownfield project using 3D scanning |
Introduction to AtkinsRéalis | Overview of the company and its services |
Q&A | Question and Answer session |
Date: Friday, September 6th, 13:00-14:30
Location: Convention Hall B, International Conference Center
We also introduce highlights of JASIS2024 here.
Contact Us
For more information about products and services, please contact us at yamato-net.co.jp.