Plant Visualization Reduces Customer Risk for PFi

With the large upfront costs often involved in new plant automation solutions, problem-solving engineering company, Products For Industry (PFi), based in Queensland, Australia, has found a way to provide its customers with additional certainty, and reduced risk.

PFi employs Emulate3D by Rockwell Automation to create a digital twin, and completely visualize a new or upgraded plant, prior to the physical implementation.

Using 3D CAD modelling and integrated automation software, Emulate3D allows users to test the entire production process virtually, which helps to optimize the solution to save customers space, time, downtime, energy usage, and cost.

Gavin Dunwoodie, managing director, PFi, said, “More and more customers are asking for a simulation during the tender process, so if we can show exactly how well our solution will work, the ROI they are likely to achieve, and that we are meeting industry best practices, it gives us a real competitive advantage. We use Emulate3D software during the tender process to visualize customer operations using our machinery as part of our pitch.”

“Since incorporating Emulate3D into the process, we have seen a greater win rate, as customers can see the product working before they purchase. Yes, there are upfront costs, but they pay dividends as the customer is willing to pay a premium to see that the product produces needed, and often increased results,” added Dunwoodie.

PFi is a locally owned and operated business servicing the industrial sector. The company offers a full suite of in-house capabilities to support manufacturers with machine automation products, systems and solutions.

For brand new plants or automation retrofits, PFi uses Emulate3D to showcase exactly how the new plant will run, down to the finest details.

“The details you can include in the software are incredible. If you’re handling frozen food, for example, we can simulate that melting could cause condensation, which would warp the shape of a cardboard container, which would impact how it travels along a conveyor. All of this can be simulated, realistically, using Emulate3D, and we can then recommend that a customer select a different packaging type to ensure product integrity and efficient delivery. The same goes for if our engineers believe they can tweak the machine or other operating variables to increase production or uptime – the customer is always excited when we over-deliver,” said Dunwoodie.

Software Drives Business Growth

In addition to using Emulate3D as a value-add to customers, or as a tool to win tenders, PFi also uses it to help their own business grow. Just seven years ago, PFi had 26 employees, and today, it has more than 250.

Dunwoodie shared that key to the company’s strong growth has been reputation management, and staff retention. “Emulate3D has enabled us to test solutions before delivering them, meaning that we are only ever delivering quality solutions that are proven to work, and this means we maintain an excellent reputation in the industry.”

“Further, I’ve always believed staff are the heart of any business, and staff retention is critical to business growth. Engineering and automation staff, in particular, want to work with the latest tools, so by investing in Emulate3D, we’re investing in keeping our staff,” he said.

Gary Tyson, senior associate, packaging and materials handling, BECA, has discovered the added value of involving Emulate3D in the tender process. “Using Emulate3D during the tender process gave us a clear visualization of the solution to be provided, and it allowed us to review and eliminate any bottlenecks before presenting an optimized solution to the end-user,” said Tyson.

BECA is an engineering and professional services consultancy firm widely used by industry, and they contract PFi for individual projects that require automation solutions. Gary believes companies like PFi should be selected based on risk, and how “true to life” the solution is. “Emulate3D reduces customer risk, and significantly helps PFi win the job, by proving their system capabilities,” he added.