The Sener group has developed and implemented a virtual representation of the facility, or digital twin, for global biopharmaceutical company Almirall. The digital twin replicates the real-time energy performance of the company’s plant in Sant Andreu de la Barca, Barcelona. Using this digital twin, the solution analyses multiple operational variables and directly controls the equipment to autonomously optimise the energy systems, maximise efficiency and reduce consumption.

The digital twin is directly connected to the plant’s equipment and systems, making it possible to continuously process the data and automatically adjust the operation of the facility. This capability allows plant personnel to focus their efforts on more efficient and strategic oversight, while the system continuously optimises operations.

The implementation of this project has had a tangible impact on the plant’s energy operations. Since implementation in the third quarter of 2025, Almirall has reduced gas consumption by more than 60% compared with 2019 levels, while producing 20 million more units of product than in the same year, exceeding initial projections. In addition, since the solution began controlling the steam generation system, the efficiency of the process has doubled compared with the previous year. These advances not only reduce consumption and improve the performance of the facility, but also strengthen Almirall’s ability to advance the decarbonisation and energy efficiency of its industrial operations in line with its Act4Impact sustainability strategy.

The goal: optimise a highly complex energy system

Managing the energy systems of a pharmaceutical plant requires the continuous coordination of multiple systems that can generate steam, cooling and heat for climate control, hot water and compressed air. The range of generation systems available for the same utility, combined with the large volume of data and variables that affect their efficiency, makes it impossible for a human team to analyse them all in real time and determine the most efficient generation configuration at any given moment.

To address this challenge, Sener’s digital twin combines advanced energy modelling, data analytics and integration with the plant’s control systems. The solution replicates the facility’s performance in real time and, unlike other optimisation tools, does not simply provide recommendations. It automatically implements decisions on the equipment to keep operations running at optimal efficiency.

Another key aspect of this solution is its scalability across other production sites and its ability to evolve over time. In future phases, Almirall plans to extend the Energy Digital Twin to control all the plant’s air handling units – more than 270 units – optimising their operation while maintaining required comfort and environmental conditions at the lowest possible energy and environmental cost. This evolution will be supported by an intelligent control system capable of creating thermal storage, making the most of surplus solar generation and periods when electricity rates are most favourable.