Before reorganizing a warehouse or redesigning transport routes, what if you could test everything first... in a virtual replica? That’s possible thanks to digital twins: virtual models of fleets, logistics centers, and supply chains that act as testing labs — risk-free and without disrupting real-world operations.

Companies use these simulations to detect inefficiencies, anticipate problems, and validate decisions before implementing them. All with real-time, real-world data.

What are digital twins used for in logistics?

With a digital twin, you can test the design of a new warehouse without moving a single pallet. Or redraw transportation routes without burning a single drop of fuel.

They are used to detect bottlenecks, prevent stockouts, and improve inventory management. They also help predict when automated equipment might fail or how much energy is being wasted. That’s why more and more logistics companies are using them to plan new facilities, review processes, or adjust daily operations in real time.

The intralogistics company Mecalux, based in Cornellà de Llobregat (Spain), has developed several digital twin projects to enhance warehouse performance:

• At the Congelados Navarra plant, they created a virtual replica to validate the operation of the automated warehouse before installing physical equipment on site. This helped avoid implementation errors and shortened commissioning times.
• At a Rossignol facility — a French brand specializing in ski and winter sports gear — Mecalux used a digital twin to reinforce the warehouse’s structural safety. The site, located in Saint-Étienne-de-Saint-Geoirs, a southeastern French area with moderate seismic risk, required an earthquake-resistant design. The virtual model allowed them to simulate seismic scenarios, validate rack strength, and ensure compliance with European safety standards.

The global logistics operator CEVA Logistics implemented a digital twin in its distribution center in Brandenburg, Germany — specialized in retail and fast fashion — to anticipate demand spikes and better plan daily work. Thanks to this tool, based on dynamic simulation and connected to real-time data, they can adjust shifts, minimize bottlenecks, optimize every operational phase, and reduce risks without disrupting activity. The result? 200 weekly labor hours saved and 2% more operational capacity.

In a sector with tight margins and complex decisions, digital twins allow companies to fine-tune processes without interrupting day-to-day logistics operations.