DigiTwin - for Pharma

DigiTwin for Pharma

Complete simulation of the FAT process, including the wet phase, without the need for water or manual cleaning before shipment

A Fully Simulated WET FAT with Zero Water Consumption with DigiTwin

At a Tier 1 European pharmaceutical manufacturer, MGA implemented a Digital Twin of a new skid composed of ProX90 (reverse osmosis) and EDI (electrolytic filter).

Using a physical PLC and a virtual HW-in-the-loop environment, the dynamic behavior of the machine was digitally simulated, allowing for advanced testing and unprecedented WET FAT optimization.

Client: Pharma Europa Tier 1

Location: Italy

Technologies: Digital Twin (HW-in-the-loop), PLC, Reverse Osmosis (ProX90), EDI

Scope: FAT simulation, automation testing, cost & time optimization

Simulated WET FAT with DigiTwin

Factory Acceptance Testing (FAT) is a critical step in validating automated systems before shipment. Traditionally, WET FAT involves full testing with liquids, making it the most complete and realistic—but also the most resource-intensive and expensive—approach.

Using our Digital Twin technology, we recreated a full WET FAT experience virtually—without introducing a single drop of water into the system. The DigitTwin allowed us to simulate liquid behavior, process sequences, and control responses in real-time, offering the same reliability as a traditional WET FAT but at a fraction of the cost and effort.

saving on FAT execution time

Operational sequences were accelerated thanks to the digital model.

total cost saving

in labor and consumables (e.g. water, energy, membranes) compared to a traditional WET FAT

punch list reduction

After VIT (Vendor Internal Test)

DigiTwin for Pharma

Simulated WET FAT with DigiTwin

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