Real-Time Predictive Digital Twin

Your process,
mirrored.
Failure, predicted.

When inlet temperature drifts 2°C, Twynvex shows you the yield impact 4 hours downstream — before the batch report tells you it already happened.

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Industrial digital twin dashboard showing a reactor train with real-time telemetry overlays and predictive yield curves
The Reporting Gap
Batch reports arrive after the damage. The off-spec product is already in the hold tank.
Reactive Alarms
Sensor alarms trigger response, not prevention. By the time you know, the window is closed.
Slow Root Cause
Variance root-cause analysis takes days to trace through historian data and shift logs.
How Twynvex Works

A real-time digital twin that runs ahead of your plant.

Step 1
INGEST
Sensor streams via OPC-UA, MQTT, Modbus, and REST. No middleware required.
Step 2
MIRROR
Physics-based process model updates every 15 seconds from live sensor data.
Step 3
PREDICT
Yield, energy, and quality projections 2–6 hours forward — before the batch report.

Unlike statistical models trained on historical data, Twynvex encodes the actual governing equations of your unit operations — heat and mass balance specific to your reactor train, distillation column, or evaporator. When feedstock composition shifts or ambient temperature changes, the model responds the way your process does, not by extrapolating a regression it hasn't seen before. And when the prediction diverges from reality, the model tells you which variable is responsible.

Platform Capabilities

Precision tooling for continuous-process engineers.

Physics-Based Simulation

Not a statistical black box. Our models encode heat and mass balance equations specific to your unit operations.

Predictive Horizon

2 to 6 hours of actionable lookahead. Know the impact of a setpoint change before you make it.

Multi-Protocol Ingest

Native OPC-UA, MQTT, Modbus TCP, and REST. Connect your historians and SCADA without middleware.

Deviation Alerts

Configurable alert thresholds tied to predicted outcomes, not raw sensor thresholds.

Operator Dashboards

Purpose-built displays for DCS operators. Not a BI tool. A control-room interface.

Audit Trail

Every model state change and alert logged with timestamp and sensor provenance.

Built For

Continuous-process industries where variance costs millions.

Chemical

Distillation columns, reactor networks, and yield optimization. Feed variability and ambient temperature effects — modeled and predicted.

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Food & Beverage

Evaporators, pasteurizers, and fermenters. Batch-to-batch consistency and steam consumption — tracked against predicted targets.

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Pharma

Bioreactors, lyophilizers, and critical process parameters. Physics-based predictions aligned to your process understanding.

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Designed for Precision
2–6 hr
Predictive lookahead window — yield, quality, and energy
15 sec
Twin update cycle — physics model synced from live sensor data
<200 ms
Alert-to-dashboard latency — from deviation detection to operator screen

Built on a continuous-integration simulation core — not a batch analytics pipeline that reports yesterday.

Ready to stop reacting and start predicting?

We work with a small number of pilot plants directly. If your facility runs a continuous process, let's talk.

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