Industrial solutions for monitoring, safety, and real-time operations.
Build a scalable, multi-user software that helps your business monitor factories, machines, and compliance in real time.
About
Zwillio
Digital Twin Platform
Core Modules
The foundation of the Zwillio engine.
Data Integration
Connect your sensors, legacy machines, and enterprise software into one real-time digital stream.
AI & Analytics
Turn data into actions with AI models that learn from your environment.
Multi Level Visibility
Track performance from a single asset to your entire global operation in one clear, customized view.
Response System
Prevent downtime with alerts that notify your team when a threshold is met.
Core Modules
Visualizing your data in action.
Shopfloor Perspective
Gain complete oversight of floor operations with real-time heatmaps and interactive 3D process models.
Workflow Optimization
Analyze end to end production cycles to identify bottlenecks and simulate future operational scenarios.
Asset Health Diagnostics
Access deep dive performance metrics for individual machines to maximize reliability and equipment life.
Core Modules
Visualizing your data in action.
Smart Factory
Gain complete oversight of floor operations with real-time heatmaps and interactive 3D process models.
Process Optimization
Analyze end to end production cycles to identify bottlenecks and simulate future operational scenarios.
Machine Health
Access deep dive performance metrics for individual machines to maximize reliability and equipment life.
Connect your sensors, legacy machines, and enterprise software into one real-time digital stream.
Data Integration
Turn data into actions with AI models that learn from your environment.
AI & Analytics
Prevent downtime with alerts that notify your team when a threshold is met.
Response System
Track performance from a single asset to your entire global operation in one clear, customized view.
Multi-Level Visibility
Core Modules
Data Integration
Connect your sensors, legacy machines, and enterprise software into one real-time digital stream.
Multi-Level Visibility
Track performance from a single asset to your entire global operation in one clear, customized view.
AI & Analytics
Turn data into actions with AI models that learn from your environment.
Response System
Prevent downtime with alerts that notify your team when a threshold is met.
Core Modules
Data Integration
Connect your sensors, legacy machines, and enterprise software into one real-time digital stream.
Multi-Level Visibility
Track performance from a single asset to your entire global operation in one clear, customized view.
AI & Analytics
Turn data into actions with AI models that learn from your environment.
Response System
Prevent downtime with alerts that notify your team when a threshold is met.
Operational Intelligence
Visualizing your data in action through our Zwillio dashboards
Gain complete oversight of floor operations with real-time heatmaps and interactive 3D process models.
Access deep dive performance metrics for individual machines to maximize reliability and equipment life.
Asset Health Diagnostics
Shopfloor Perspective
Workflow Optimization
Analyze end-to-end production cycles to identify bottlenecks and simulate future operational scenarios.
Operational Intelligence
Visualizing your data in action through our Zwillio dashboards
Shopfloor Perspective
Gain complete oversight of floor operations with real-time heatmaps and interactive 3D process models.
Workflow Optimization
Analyze end-to-end production cycles to identify bottlenecks and simulate future operational scenarios.
Asset Health Diagnostics
Access deep dive performance metrics for individual machines to maximize reliability and equipment life.
Operational Intelligence
Visualizing your data in action through our Zwillio dashboards
Gain complete oversight of floor operations with real-time heatmaps and interactive 3D process models.
Analyze end-to-end production cycles to identify bottlenecks and simulate future operational scenarios.
Access deep dive performance metrics for individual machines to maximize reliability and equipment life.
Benefits for Industries
Purpose built solutions for high-stakes industries.
Directive Maintenance
Predictions to provide the maintenance sequence required to protect heavy haul fleet.
TreadZ
Smart Tire Intelligence
Real time health tracking for heavy haul tires to prevent blowouts and reduce replacement costs.
Features
The measurable impact for your enterprises.
Lower Production Costs
Downtime Reduction
Safety & Compliance
System Resilience
Scrap Reduction
Increased Quality
Lower Utility Consumption
Lower Carbon Footprint
Who can benefit?
Our solution can help factory floor engineers and technicians, maintenance teams, reliability engineers, and line supervisors who need real-time visibility, as well as process/quality engineers who want to optimise parameters and minimize variation with predictive intelligence and closed-loop control. Manufacturing companies with production lines, heavy machinery, and multi-workshop plants (in automotive, heavy equipment, tyre, machine tools, etc) can deploy our solutions seamlessly.
Industries we serve
Purpose built solutions for high-stakes industries.
MinePulse
Predictions to provide the maintenance sequence required to protect heavy haul fleet.
How it Works
From data to decisions in four steps, our integrated platform transforms your physical operations into intelligent digital systems
Data
Collection
Specialized hardware collects real-time data from your physical assets and environments
Processing
& Analysis
Advanced AI algorithms process and analyze data streams in real-time
Digital Twin Creation
Creates accurate virtual replicas of your physical systems with live synchronization
Actionable
Insights
Receive predictive alerts, recommendations, and automated responses
Technical Approach
How we built Zwillio
Platform-independent, open-source foundation to ensure total data ownership
High-performance data engine built to handle volumes of industrial time series data with low latency.
Secure deployment across on premise servers, local edge environments, or private cloud architectures.
Features in-house hardware and firmware
using vibration, pressure, temperature and other
sensors for capturing high-frequency data
Operational Efficiency
By optimizing workflows and identifying bottlenecks early, we help your team Improve productivity and reduce downtime
Reliable & Scalable
Our software ecosystem is designed to scale across multiple sites, teams, and geographies, ensuring consistent performance.
Enhanced Safety
Monitor safety and security processes in real time to reduce operational risk, while protecting your assets and personnel.
Actionable Data
Transform raw, centralized data into AI-driven planning, providing predictive maintenance to achieve long-term goals.
Why Choose Us
Experience the advantages of digital twin technology designed for reliability, security, and performance at scale
Real-time monitoring of legacy machines with no digital footprint
Supports multiple communication protocols (Modbus, OPC-UA, MQTT, APIs, etc.)
Single platform to monitor and manage all systems with realtime customisable alerts
Role-based access for managers, engineers, and operators
AI models fine-tuned on customer data for higher accuracy
Platform-independent & open-source foundation
PostgreSQL + TimescaleDB for large-scale time-series data
Docker-based architecture for scalability and easy deployment
Supports on-premise and local server hosting
In-house hardware and firmware for sensors like temperature, pressure, vibration, and current
Technical Approach
The technology approach that Zwillio follows
Platform platform-independent, open-source foundation to ensure total data ownership
High-performance data engine built to handle volumes of industrial time series data with low latency.
Secure deployment across on premise servers, local edge environments, or private cloud architectures.
Features in-house hardware and firmware for sensors like temperature, pressure, vibration, and current
