Advances in energy management: the role of digital twin technology

Optimizing energy management is a key challenge for modern companies. The continuous development of digital technologies is opening up new opportunities to improve the efficiency and sustainability of energy management systems. One promising approach is the use of digital twin technology.

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Digital twin technology in energy management

A digital twin is a virtual representation of a physical object or system. In the context of energy management, this technology enables precise allocation of energy data to specific production processes, products or orders. By continuously recording and analysing real-time data, companies can better understand and optimize their energy flows.

The advantages of digital twin technology in energy management include:

  • Transparency and control: By visualizing and monitoring energy flows in detail, companies can identify inefficient processes and make targeted improvements.
  • Forecasting and planning: With the help of simulations and forecasting models, future energy requirements can be predicted and optimally planned.
  • Cost savings: Significant cost savings can be achieved by reducing energy losses and optimizing energy use.
  •  Sustainability: Efficient energy use helps to reduce the carbon footprint and supports companies in achieving their sustainability goals.
Energy data

Standards and certifications

The implementation of an effective energy management system requires compliance with international standards. DIN EN ISO 50001 is a globally recognized standard that helps companies to systematically improve their energy efficiency. Certification in accordance with this standard confirms that a company has established an effective energy management system that ensures continuous improvement. 

In order to be recognized as eligible, energy management software solutions must meet certain criteria. These are checked by accredited conformity assessment bodies to ensure that the software supports the requirements of DIN EN ISO 50001.

Recognition by BAFA

In Germany, the Federal Office of Economics and Export Control (BAFA) plays a central role in the promotion of energy management systems. Software solutions that are recognized as eligible for funding by BAFA offer companies additional incentives to implement efficient energy management practices.


Our contribution: OPD.EnergyData

Against this background, we are pleased to announce that our energy management software OPD.EnergyData has received final approval from BAFA and is now listed as eligible energy management software. This recognition confirms that our software fulfills the necessary functionalities for DIN-EN-ISO-50001 conformity.

Energy-related aspects of retrofitting in raw materials handling

Energy sources

Solar energy:

Installing solar modules on the roofs of warehouses or plant buildings can contribute to self-sufficiency and reduce the need for grid electricity.

Wind energy:

In suitable locations, the installation of wind turbines can provide a sustainable source of energy.


Use of biomass plants to generate energy from organic waste or by-products of production.


Energy mix and storage:


Battery storage:

Storage of surplus energy from renewable sources for use at peak load times or during power outages.

Combination of energy sources:

A diversified energy mix of solar, wind and possibly conventional sources ensures a stable and reliable energy supply.


Energy consumption


Energy-efficient drive systems:

Modern motors:

Use of energy-efficient motors that consume less power and offer higher performance at the same time.

Frequency inverter:

Control of the motor speed as required, which significantly reduces energy consumption.


Process optimization and automation:

Automated control systems:

Precise control and monitoring of processes to avoid wasting energy.

Intelligent sensor technology:

Use of sensors for real-time monitoring and optimization of energy consumption in various process stages.


Heat recovery:

heat exchanger:

Recovery and reuse of waste heat from production processes for heating or power generation.

Insulation improvements:

Reduction of heat loss through better insulation of systems and pipes.


Energy monitoring and management:

Energy audits:

Regular reviews of energy consumption to identify potential savings.

Energy Management Systems (EMS): Implementation of EMS for continuous monitoring and optimization of energy consumption.

Integration into the value stream and raw material handling

The digital twin and the digital product passport offer enormous advantages in the value stream and raw material handling. They make it possible to monitor and optimize all steps from the receipt of raw materials through production to delivery. By integrating them into the value stream, companies can:

  • Identify and eliminate bottlenecks: Real-time data enables precise monitoring of production processes, allowing bottlenecks to be quickly identified and rectified.
  • Continuously improve processes: By analyzing the collected data, companies can continuously optimize and adapt their processes to increase efficiency and productivity.
  • Making sustainable decisions: Transparent and consistent data along the value stream and in raw material handling support sustainable decisions and help to minimize the ecological footprint.

Mindfulness and collaborative working - Focus on energy


In today's world, efficiency and sustainability are crucial in energy management. Mindfulness and collaborative working play an important role in optimizing energy consumption.

Mindfulness in energy management

Create awareness:

Training to raise employees' awareness of their energy consumption.

Regular updates on energy-saving targets and results.

Promote a sense of responsibility:

Integrating energy-efficient practices into everyday working life.

Incentives for proactive action, such as switching off unused appliances.

Collaborative working in energy management

Interdisciplinary teams:

Teams from different departments work together on energy-saving projects.

Use of different expertise to develop innovative solutions.

Set common goals:

Definition and pursuit of joint energy saving targets.

Regular meetings to review progress and develop new strategies.

Open communication:

Promoting an open exchange of ideas and feedback.

Use of platforms for collaboration and the exchange of ideas.

Industry data as the basis for the digital product passport

Important links and resources

For more information and detailed specifications you can visit the following links:







By focusing on optimizing energy consumption and integrating sustainable energy sources, retrofit projects in raw materials handling can make a significant contribution to reducing operating costs and improving the ecological balance sheet. These measures not only help companies to comply with legal requirements, but also to achieve their sustainability goals.

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