In turnkey food factory projects, the commissioning and operator training processes that occur after physical construction and machine assembly are completed are critically important but also constitute a significant pressure point on the project timeline. This article examines how Augmented Reality (AR) technology, particularly industrial AR glasses, is radically transforming these processes. The technical details of how training operators using AR glasses on a digital twin while the physical factory is being built can shorten commissioning time by up to 40%, reduce error rates, and increase maintenance efficiency will be discussed.

Challenges in the Traditional Commissioning Process

In a turnkey food factory, the commissioning process that begins after all equipment is installed and physical tests are completed is often the most significant bottleneck of the project. The traditional challenges encountered in this process are:

• Delay in Operator Training:Operator training begins only when the physical machinery is ready for use. This coincides with the final stages of the project, and any delay impacts the entire project delivery date.
• Inadequacy of “Paper-Based” Procedures:The operating principles of complex equipment such as CIP (Clean-in-Place) systems, homogenizers, or aseptic filling lines can remain abstract for operators when explained through printed documents, steepening the learning curve.
• High-Cost Errors:Minor mistakes made by inexperienced operators on real equipment (e.g., turning the wrong valve, missing a temperature setting) can lead to significant production losses, quality problems, and even safety risks.
• Learning Maintenance Procedures:It is difficult for maintenance teams to be prepared for rarely encountered fault conditions. Following maintenance instructions via static PDFs or manuals is inefficient and prone to error.

A Technical Look at Augmented Reality (AR) and Digital Twin Technology

Industrial Augmented Reality (AR):
Industrial AR allows the user to see a real-time view of the physical world enriched with digital information (3D models, animations, data points, instructions). This technology is used in industrial environments with devices such as Microsoft HoloLens 2, RealWear HMT-1/Z1, and Magic Leap.

• SLAM (Simultaneous Localization and Mapping):This algorithm, which forms the foundation of AR devices, enables the device to recognize the physical environment, map it, and accurately “anchor” digital content onto it.
• Computer Vision:The device can recognize physical objects (e.g., a pump or control panel) through its cameras and retrieve information specific to them.

The Factory’s Digital Twin:
A digital twin is a software copy of the physical factory or a piece of equipment, simulated one-to-one with all its dynamics. This model is fed with PLC (Programmable Logic Controller) data, SCADA (Supervisory Control and Data Acquisition) systems, and CAD (Computer-Aided Design) drawings, making it a complete reflection of its real-world counterpart.

AR-Supported Processes: Virtual Training Simultaneous with Physical Installation

The main idea is to start the training of operators and maintenance teams immediately, while the physical factory is being constructed.

Training on the Virtual Floor:

• Process:The factory’s digital twin is prepared for AR glasses. Operators, wearing AR glasses in an empty space (e.g., an office or training room), can “see” the entire production line, equipment, and piping that has not yet been installed, in 3 dimensions.
• Application:An operator can start a virtual homogenizer, change temperature settings, or initiate a CIP cycle using hand gestures or voice commands. The system provides feedback at every step. For example, it gives a warning if an incorrect sequence is followed or shows how the system reacts in the simulation (e.g., pressure drop, temperature increase) if a valve is turned in the wrong direction.
• Technical Benefit:Operators get the chance to practice “dry-running” hundreds of times without touching physical equipment. This builds muscle memory and increases confidence.

Guided Procedures with AR on the Physical Floor:
After the physical factory is built, the role of AR becomes even more concrete.

• Step-by-Step Operational Instructions:While an operator performs the startup procedure of a filling machine, the AR glasses display which button to press, which valve to turn, and which parameters to check, using arrow signs, animations, and 3D arrows.
• Real-Time Data Visualization:When an operator looks at a tank, the AR glasses display the tank’s internal temperature, level, and fill rate as a floating data panel above the tank. This eliminates the need to constantly look at SCADA screens.

• Remote Assistance:In the event of a problem, an operator on-site can establish a live video connection with an expert in the central office or at the supplier firm via the AR glasses. The expert can draw digital annotations (circles, arrows) on the operator’s live view to point out the faulty component and explain the solution. This dramatically reduces travel costs and intervention time.

The AR Revolution in Maintenance Procedures

AR is becoming central to preventive and predictive maintenance strategies.

• Visual Guide for Complex Maintenance Operations:When a centrifugal pump needs to be disassembled and maintained, the maintenance technician is provided with step-by-step instructions via AR. Which bolt to remove, the disassembly sequence, and torque values are displayed over the real pump.
• Parts Identification and Inventory Management:When a technician looks at a piece of equipment, the AR glasses show the stock code of the relevant part, its location in the warehouse, and spare parts information if available.
• Sensor Data and IoT Integration:When vibration or temperature data from IoT sensors on a machine shows an abnormal value, the AR glasses alert the technician and provide visual guidance pointing to the potential source of the problem.

 Process Acceleration and Measurable Benefits

The acceleration and benefits provided by an AR-supported commissioning process can be measured as follows:

• Reduction in Commissioning Time (30-50%):Since operator training starts simultaneously with physical installation, the teams are already ready when the factory is built. A traditional 8-week training and commissioning period can be reduced to 4-5 weeks with AR.
• Increase in Operator Competence (50%+):Visual and interactive learning provides an increase of over 50% in knowledge transfer and improves knowledge retention rates.
• Reduction in Operational Errors (40%+):Practice in the virtual environment and guided procedures on the physical floor minimize human-induced errors.
• Shortening of Maintenance Durations (25-35%):Faster and more accurate completion of maintenance procedures shortens planned downtime.
• Reduced Dependence on Documentation:Operators and technicians work with dynamic, contextual information that appears when needed, instead of thousands of pages of manuals.

Future Perspective

Augmented Reality has become not just an “improvement” tool but a “transformation” technology in turnkey food factory projects. This approach, which merges the physical and digital worlds, eliminates the usual bottlenecks of the commissioning process, enabling projects to be implemented faster, safer, and more efficiently.

In the near future, it is anticipated that AR systems, further empowered by Artificial Intelligence (AI), will not only give instructions but will also analyze the operator’s actions to provide proactive suggestions, and even offer decision support in areas like predictive maintenance. For every company seeking to create a competitive advantage in the food sector, AR-supported digital transformation strategies are no longer a luxury, but a necessity.