Simulation and Virtual Commissioning Services
Modern industries demand smarter, faster, and more reliable automation solutions. At NOVIMEQ Automation, we make it possible through advanced Simulation, Emulation and Virtual Commissioning Services. By combining industrial experience with digital innovation, we help organizations validate their automation systems before actual deployment, saving time, cost, and effort.
As a Digital Engineering System Integrator Partner of Rockwell Automation, NOVIMEQ leverages the power of Emulate3D and other digital tools to create accurate virtual environments. These environments replicate machine and plant behavior, allowing complete control system testing before real-world commissioning.
Emulate3D allows NOVIMEQ to build accurate, physics-based digital models of machinery and production lines before they are deployed on the shop floor. By creating a dynamic 3D environment, we can test PLC logic, validate interlocks, check material flow, and simulate real-world machine behavior early in the engineering cycle. This reduces rework, cuts commissioning time, and gives OEMs and end users a clear operational view of the system, long before the equipment arrives on site. Emulate3D also helps identify bottlenecks, safety risks, and performance gaps, enabling a smoother transition from design to commissioning.
NOVIMEQ’s Simulation and Virtual Commissioning Capabilities
- Virtual Commissioning – Test and validate PLC logic, HMI, SCADA, and robotics integration virtually, reducing on-site commissioning time.
- Machine Simulation – Digitally model and validate machines to identify issues early and minimize physical prototyping costs.
- Process Improvement – A analyze automation workflows and optimize processes for higher throughput and reliability.
- Throughput Analysis – Evaluate cycle times, detect bottlenecks, and improve line efficiency before commissioning.
- Operator Training Simulators – Train plant operators in a safe, simulated environment to ensure readiness and reduce on-site learning time.
- MES/WMS Integration – Connect simulation environments with MES/WMS systems for end-to-end production validation.
- Analytics – Use simulation-driven data insights to improve design accuracy and operational decision-making.
- Headcount Analysis – Assess manpower requirements and optimize human–machine collaboration for better productivity.
- Digital Twin Simulation – Create a virtual twin of machines or production lines for real-time testing and process optimization.
NOVIMEQ’s Key Services for Simulation, Emulation & Virtual Commissioning
NOVIMEQ delivers a complete suite of Simulation, Emulation, and Virtual Commissioning solutions designed to accelerate automation deployment, reduce engineering risk, and ensure flawless system performance before live commissioning. Our services support OEMs, system integrators, and manufacturing industries seeking faster execution, improved safety, and greater operational reliability.
• 3D Emulation and Digital Testing
NOVIMEQ builds accurate 3D emulation models and physics-based digital environments of machinery, production lines, and robotics systems to validate performance before installation. Using Emulate3D and industry-leading simulation tools, we test PLC logic, interlocks, sequencing, safety constraints, and operational workflows under multiple scenarios.
With proven experience in projects such as robotic bale de-wiring, billet handling automation, and anode slot cutting systems and ongoing automotive applications, NOVIMEQ enables clients to detect design gaps early, eliminate risks, and shorten deployment timelines. This simulation-first approach minimizes rework, improves system reliability, and ensures plants achieve operational readiness faster and more cost-effectively.
• Virtual Commissioning with Emulate3D
Through advanced Virtual Commissioning workflows, NOVIMEQ connects emulation models directly to real PLCs and control systems to verify functionality before equipment reaches the shop floor. Using digital twins and Emulate3D, we simulate real-world conditions, machine behavior, cycle times, and logic execution to ensure seamless control integration.
This approach significantly reduces onsite commissioning time, prevents unexpected failures, and accelerates the transition from engineering to full production—enhancing safety, efficiency, and project predictability.
• System Design and Technical Consultancy
NOVIMEQ offers expert engineering consultancy to help OEMs and manufacturers design automation systems optimized for simulation and virtual commissioning. We provide feasibility studies, workflows, standards documentation, and engineering support to ensure systems are simulation-ready from the earliest design stage.
Our design-for-virtual-commissioning methodology helps organizations establish scalable, repeatable, and high-performance engineering frameworks.
• Emulate3D Training and Skill Development
NOVIMEQ also provides professional Emulate3D Training Services for OEMs, automation teams, system integrators, and engineering departments. Our hands-on training programs help engineers and technicians learn how to build accurate machine simulations, digital twins, controls emulation models, and throughput analysis using Emulate3D.
What we cover:
- Introduction to Emulate3D software
- Building 3D machine models
- Logic testing through PLC Emulation
- Controls testing with real controller connections
- Virtual Commissioning workflow
- Debugging automation logic inside a simulated environment
- Best practices for model optimization & performance tuning
Our training improves engineering productivity, reduces trial-and-error, and equips teams to run Virtual Commissioning independently.
To empower engineering teams, NOVIMEQ provides specialized training in Simulation, Digital Twin, Emulate3D, Control System Testing, and Virtual Commissioning workflows. Our hands-on programs are designed for OEM teams, system integrators, and industrial automation professionals—helping them confidently build, simulate, test, and maintain their own digital automation environments.
Why Simulation, Emulation and Virtual Commissioning Matters
Implementing Simulation, Emulation and Virtual Commissioning Services brings measurable improvements across design, testing, and operation.
Benefits of Simulation and Virtual Commissioning
Implementing Simulation and Virtual Commissioning Services brings measurable improvements across design, testing, and operation.
- 40-50% Faster On-Site Commissioning – Reduce project execution time by identifying and solving issues early.
- Early Bug Fixes & Optimization – Detect control logic or mechanical errors before equipment reaches the shop floor.
- Operator Training Simulators – Train operators and technicians safely in a virtual setup before real startup.
- 70% Reduction in Simulation Coding Time – Speed ??up engineering with reusable and standardized simulation templates.
- Process Improvement & Analytics – Identify system bottlenecks and optimize throughput.
- Lower Engineering Costs – Reduce design rework and hardware trials.
- Zero Downtime Risk – Achieve stable startup and error-free operation during commissioning.
Case studies – Simulation, Emulation and Virtual Commissioning Services
Case Study: From Writing A Manual Simulation Code To Virtual Commissioning
Discover how NOVIMEQ Automation delivered its first successful virtual commissioning proof-of-concept (POC) in 2021 for a US-based manufacturer using Rockwell’s Emulate3D. This innovative approach to simulating the Billet Handling System enabled 40-50% faster commissioning, reduced coding time, and helped eliminate costly on-site errors.
Case Study: Batch Homogenizing Load Transfer Car
This virtual commissioning environment allowed us to identify and resolve issues early, confirm system performance, and validate the overall design before deployment on the actual equipment.
Assembly and Inspection lines simulation
T he simulation allowed the team to analyze bottlenecks, validate layout decisions, predict throughput, and optimize resource allocation, ultimately supporting a smoother, safer, and more efficient assembly process before actual implementation.
Industries We Support
NOVIMEQ delivers Simulation, 3D Emulation and Virtual commissioning solutions tailored to the unique needs of global industries. With strong domain expertise and experience across diverse manufacturing environments, we help organizations accelerate deployment, improve reliability, and optimize plant performance before equipment arrives on-site.
- Food & Beverage
- Automotive & EV Manufacturing
- OEM Manufacturing
- Metals & Foundry
- Heavy Machinery Manufacturing
- Aluminum Extrusion & Rolling Mills
- Pulp & Paper Manufacturing
- Robotics & Material Handling
Why Choose NOVIMEQ for Simulation, Emulation and Virtual Commissioning Services
NOVIMEQ brings years of hands-on industry experience in Simulation and Virtual Commissioning
Services . Our engineers are proficient with Emulate3D , Rockwell Automation tools , and multiple
industrial platforms, ensuring your systems are tested and optimized virtually before they go live.
- Strong foundation in Digital Twin Simulation and Emulate3D technology
- 50+ successful virtual commissioning projects across various industries
- Deep understanding of automation, process simulation, and control testing
- Virtual commissioning of conveyor systems, AGVs, and automated production lines.
- Expertise in Rockwell Automation platforms and integration with PLC, SCADA, and MES systems
- Proven track record in reducing commissioning time, risk, and engineering effort
- Throughput analysis and headcount evaluation to optimize plant operations.
- Analytics and scenario-based testing for continuous improvement.
Connect with NOVIMEQ today to start your Simulation and virtual commissioning journey.
Bring your automation systems to life before they even hit the factory floor. Partner with NOVIMEQ Automation for next-generation Simulation & Virtual Commissioning Services and experience a smarter, faster, and safer way to design and validate automation.
+91 8956 402 701 / +91 8983 267 998
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