This case study shares our first proof-of-concept (POC) from 2021 for a US-based manufacturer.

At a glance:

Project: Billet Handling System – commissioned in USA

Solution: Virtual Commissioning with Rockwell’s Emulate3D 

Key Wins: 40-50% faster commissioning

Tools: Emulate3D, Studio 5000 and FTView ME  

All innovations begin with a challenge. Innovators see challenges as opportunities to create new solutions. That’s exactly what happened during COVID-19 period. While the world was facing several barriers, we stayed focused on helping our customers keep their operations running.

But we couldn’t move forward as expected due to limited machine accessibility, shrinking project timelines, and delays in travel plans caused by government restrictions when the time arise for a commissioning of Billet handing system in USA.

To solve this, we had no choice but to write thousands of lines of code to simulate and understand the actions and reactions of each piece of equipment and field device. It was a big challenge!

There was tremendous pressure on our automation team. Not only did they had to understand the complete process, but also to write the PLC code that matches its requirements. After testing multiple scenarios, the team achieved 80% simulation accuracy, which helped us bring the system to life in just two months. This working simulation – built with actual PLC code and HMI – enabled us to complete the job smoothly and earned great feedback from our customer.

This success opened a new chapter for us when we discovered specialisd virtual commissioning software: Rockwell Automation Emulate3D. It uses a virtual replica of your machine, called a Digital Twin, connected with real process sensors, actuators, and control logic. Engineers can use it to test different scenarios, optimise cycle times, evaluate safety, and more – all without being on the plant floor. No disruption to production while evaluating and analysing scenarios.

Our first experience with 3D simulation quickly became a great case study that demonstrated the power of control testing and virtual commissioning.

By simulating and emulating real system conditions, we reduced time and avoided errors before actual commissioning. With a digital twin, we had full confidence to save commissioning time.

After this implementation, NOVIMEQ Automation took a bold step by adopting this approach for all internal delivery of all projects through EPIQ Machinery. Every automation project we work on – whether for our machines or external OEMs – we undergo virtual testing before the PLC/HMI code is released. To deliver our series we use Emulate3D software for simulation and virtual commissioning

This case study shares our first proof-of-concept (POC) from 2021 for a US-based manufacturer. It shows how we avoided issues, saved time, and delivered a ready-to-run system. For us, it’s not just work – it’s about delivering real value.

The Challenge

For our pilot project, we focused on the Short Billet Stacking Section of a Billet Saw Line – part of a larger system installed in the US in 2021.

The project involved handling and transferring vertically direct-chilled (VDC) extrusion logs from a casting machine. Operators removed the logs using an overhead crane, placed them onto a receiving station, and released them to the automated log handling system. From there, everything – load building, homogenising, cooling, cutting, and packaging – was fully automated.

Each package of billets was labelled and moved into storage manually by lift truck operators.

What made this challenging:

- The system handled different stacking patterns based on billet diameter and length.

- The stacker moved on X and Z axes using servo drives, making PLC simulation complex.

- Testing all possible combinations onsite wasn’t practical or cost-effective.

- Factory Acceptance Testing (FAT) took several weeks. Doing this virtually could save both time and cost.

We needed to test:

1. Stacking patterns for various billet sizes

2. Cycle time of the entire system

3. Bottlenecks and interlocks

Our Solution: Virtual Commissioning with Emulate3D

We started with a 3D model in SolidWorks – this included roller conveyors, a servo-driven stacker, and a turntable for strapping. We imported the model into Emulate3D and added realistic physics like weight and friction. Then, we connected it with our actual PLC logic.

After some initial trials, expanding the model and linking different system sections became easier. Traditionally, we wrote separate simulation code to mimic field devices, but for complex systems like the saw and billet handler, virtual commissioning reduced manual simulation coding efforts by more than 70%.

Also, simulation code usually assumes ideal conditions – which rarely exist onsite. Emulate3D handled variable conditions naturally, eliminating the need for complex and time-consuming scripts.

Key Benefits of Our Approach

This wasn’t just a test—it was a real showcase of what NOVIMEQ can do:

- Faster Results: Virtual testing reduced commissioning time by 40-50%.

- Lower Costs & Resource Use: Simulation coding time dropped by 70%. No billets were wasted.

- Improved Reliability: We found and fixed bugs early. Servo moves and patterns were optimised before field deployment.

- Better Training & Demos: The digital twin helped train operators and gave the customer a clear visual walkthrough of the system.

Why We Stand Out

At NOVIMEQ Automation, we live the same challenges OEMs and end users face. We know what it takes to reduce risk and deliver reliable systems.

Real Experience: We’ve tested over 50 systems – billets, rolls, slabs – for metals, pulp and paper, as well as automotive industries.

Technical Skill: Our engineers are hands-on from design to real-site commissioning experience.

Customer Focus: Whether it’s a proof-of-concept or a full install, we aim to deliver fast, budget-friendly, and lasting results.

How NOVIMEQ Can Help You

If you're facing challenges like:

1. Proving machine/process functionality before installation

2. Reducing commissioning time and avoiding errors

3. Simulating the entire process in advance

4. Testing PLC/HMI code virtually

5. Verifying safety functions

6. Training new staff using VR and simulated models

7. Gaining confidence in your system design

We're here to support you.

Customer Benefits

As part of the EPIQ Machinery group, all our stationary material handling projects undergo NOVIMEQ simulation and virtual commissioning before the machine hits the shop floor. This approach helps reduce risks, shorten commissioning time, and lower overall project costs. NOVIMEQ is also extending its support to other industries, such as automotive, tire, and other material handling sectors.

Contact Us

This Billet Handling POC is just one of the many real-world solutions we’ve delivered. We right tools, a passionate team, and hands-on experience, and we can support to do your simulation and Virtual commissioning requirements.

Tel: +91 8956 402 701 / +91 8983 267 998 

Email: novimeq@epiqmachinery.com

https://novimeqautomation.epiqmachinery.com/

LinkedIn: https://www.linkedin.com/company/novimeq-automation 

This case study is prepared by Rupali Kaushik – Director Services, at NOVIMEQ Automation

For any support and inquiries feel free to connect with Ankit Mevada and Rupali Kaushik.