Lion Bulk Handling adopts digital twins

The company says this marks a new era in bulk material handling, offering advanced tools to optimise performance, improve safety and reduce operational costs.

The digital twin replicates the behaviour and condition of critical components such as manipulator arms, using data from embedded sensors, machine learning and simulation models. “This allows operators to monitor equipment in real time, simulate different operating conditions, and detect potential issues before they occur,” said the company.

Lion Bulk Handling says it is enhancing three key areas: operational efficiency, predictive maintenance and safety. “By simulating processes and analysing real-time data, operators can identify and resolve bottlenecks, optimise material flow and increase productivity,” the company continued. The system also enables predictive maintenance by detecting early signs of wear or failure, allowing timely repairs that prevent costly downtime and extend equipment lifespan.

In addition, Digital Twins provide a safe, virtual environment for operator training. Trainees can practise and refine their skills using realistic simulations, reducing risk and improving preparedness before engaging with actual machinery.

Looking forward, Lion Bulk Handling sees the integration of digital twins as more than a technological upgrade. “It’s a strategic shift,” said the company, adding that it was aligning this innovation with other Industry 4.0 technologies, including IoT, AI and big data analytics, to create a fully connected and intelligent bulk handling network.