Digital Process Twin Cuts J&J Production Time And Costs

By Nicolas Catrysse, BD Digitalization Solutions, Siemens

Digital process twins are reshaping how pharmaceutical manufacturers move from development to commercial production. By creating a virtual replica of a chemical process, teams can predict outcomes, test scenarios, and optimize critical steps long before changes are made on the plant floor.

In this real‑world example, digital modeling was applied to one of the most time‑ and resource‑intensive phases of API manufacturing: solvent switching. The approach delivered measurable gains, including shorter processing times, lower solvent use, and reduced overall costs, while also supporting sustainability goals. Beyond optimizing existing processes, virtual experimentation enabled faster scale‑up decisions and helped avoid costly failures at industrial volumes.

As regulatory expectations and efficiency pressures continue to rise, digital twins are emerging as a practical way to improve robustness, accelerate development timelines, and bring therapies to patients faster. Explore how this approach is being applied across the pharmaceutical lifecycle.