How New Siemens Tech is Transforming PepsiCo Manufacturing

Siemens has unveiled breakthrough industrial metaverse technology – and PepsiCo is already seeing the benefits.

According to the industrial giant, Digital Twin Composer delivers “true industrial intelligence” by bringing together physical AI with the power of the most comprehensive digital twin.

Ahead of its general release, PepsiCo trialled the technology at some of its US manufacturing and warehouse facilities, achieving faster design cycles, reduced capex and identifying up to 90% of potential issues before physical build.

Industrial metaverse at scale

Digital Twin Composer builds Industrial Metaverse environments at scale, empowering organisations to “apply industrial AI, simulation and real-time physical data to make decisions virtually, at speed and at scale”.

Industrial companies can combine 2D and 3D digital twin data from Siemens’ digital twin with physical real-time information in a “managed, secure real-time photorealistic visual scene”.

The environment is built using NVIDIA Omniverse libraries.

Siemens says: “With Digital Twin Composer, companies can rapidly build and maintain this global environment, containing all aspects of their product or production data (both virtual and physical) in a secure, managed high-fidelity 3D experience, throughout the lifecycle of the product, process or facility.”

It adds: “Digital Twin Composer provides contextualised, real-time insights and intelligence enabling companies to visualise, interact with and iterate on any product, process or factory in its real-world context before physical design or construction – whether it’s a new smartphone, a tanker in a shipyard, an autonomous electric vehicle or a new AI factory on a greenfield or brownfield site.”

PepsiCo and Siemens

The partnership between PepsiCo and Siemens has seen the global drinks manufacturer convert selected US manufacturing and warehouse facilities into high-fidelity 3D digital twins that simulate plant operations and the end-to-end supply chain to establish a performance baseline.

Siemens says: “Within weeks, teams optimised and validated new configurations to boost capacity and throughput, giving PepsiCo a unified, real-time view of operations with flexibility to integrate AI-driven capabilities over time.”

Using Siemens’ Digital Twin Composer, NVIDIA Omniverse and computer vision, PepsiCo can now recreate every machine, conveyor, pallet route and operator path with physics-level accuracy.

It enables AI agents to simulate, test and refine system changes. This has delivered a 20% increase in throughput on initial deployment and is driving faster design cycles, nearly 100% design validation and 10-15% reductions in capital expenditure by uncovering hidden capacity and validating investments in a virtual environment.

Vision for the industrial metaverse

Joe Bohman, EVP, PLM Products, Siemens Digital Industries Software, says: “The new Digital Twin Composer delivers on our vision for the industrial metaverse.

“It helps manufacturers to overcome the unprecedented challenges of mastering complexity, accelerating production, reducing costs and increasing profitability.

“Siemens and NVIDIA are partnering to help manufacturers bring the most complex products, processes and factories online faster, boost resiliency and sustainability, and continuously optimise performance.”

Rev Lebaredian, VP of Omniverse and Simulation Technology, NVIDIA, adds: "In an era where every physical object and process will have a digital twin, Siemens' Digital Twin Composer establishes a digital thread that connects the silos of design, engineering and operations across the Siemens Xcelerator ecosystem.”

He says: “By integrating NVIDIA Omniverse libraries into Digital Twin Composer, enterprises can take advantage of physically accurate simulation across their workflows to validate their entire lifecycle – from product design to factory logistics – in the virtual world before committing a single atom to the real one.”

Launched at CES 2026, Siemens’ Digital Twin Composer is currently in early access with select customers.