Rockwell Automation has successfully implemented its Emulate3D™ digital twin and virtual commissioning technology for Falcare Industrial Equipment in São Caetano do Sul, Brazil, delivering substantial improvements in project execution, accuracy, and sustainability. Falcare, a long-established provider of automation solutions for retail, wholesale, food and beverage, logistics, automotive, and machinery sectors, adopted these tools to overcome challenges in physical testing, sales cycle length, field rework, and system precision.
Quick Intel
Overcoming Traditional Testing Limitations Falcare faced mounting pressure to accelerate sales cycles, eliminate implementation rework, and ensure reliable performance in complex automation systems. Previous tools fell short due to restricted modeling capabilities, poor integration between mechanical and automation elements, and data-processing constraints. Rockwell Automation's Emulate3D™ addressed these gaps by creating a dynamic digital representation that accurately simulates entire systems, allowing virtual testing of mechanical behavior, robot speeds, conveyor operations, and control logic prior to physical construction.
Key Benefits Realized The digital twin approach enabled early detection of discrepancies, validation of control sequences, and confident forecasting of system performance. This resulted in 60% faster project delivery, higher quality outcomes, and more informed decision-making throughout the engineering process. Sustainability gains emerged from reduced material waste, lower energy usage during testing phases, and more predictable operations once deployed.
Elevating Standards in Intralogistics Engineering By shifting from physical prototypes to immersive digital simulation, Falcare can now demonstrate system capabilities to customers early in the sales process, strengthen post-sales support with detailed behavioral insights, and deliver automation solutions that are faster, greener, and more dependable. This implementation stands out in Brazil, where few companies currently leverage full virtual commissioning with control logic emulation to enhance reliability and cut costs.
This collaboration highlights Rockwell Automation's role in advancing industrial digital transformation through practical, high-impact technologies that bridge design, simulation, and real-world execution.
To explore the full details of the Falcare implementation with Rockwell Automation solutions, visit the case study linked in the original announcement.
About Rockwell Automation
Rockwell Automation, Inc. (NYSE: ROK), is a global leader in industrial automation and digital transformation. We connect the imaginations of people with the potential of technology to expand what is humanly possible, making the world more productive and more sustainable. Headquartered in Milwaukee, Wisconsin, Rockwell Automation employs approximately 26,000 problem solvers dedicated to our customers in more than 100 countries as of fiscal year end 2025.
TechIntelPro empowers B2B technology decision-makers with the latest industry trends, deep insights, leadership perspectives and actionable intelligence to drive both organizational and professional milestones—and thrive on the tech pulse.