A Predictive Maintenance Approach for Composting Plants Based on ERP and Digital Twin Integration

This study presents an integrated predictive maintenance framework for industrial machinery, designed through the combined use of digital twin technology, enterprise resource planning (ERP) systems, and machine learning algorithms. The proposed system focuses on enhancing machine reliability and operational automation by connecting physical assets with their virtual counterparts and management systems. The digital twin acts as a real-time virtual model of critical equipment—such as aeration motors, mixers, and reactors—enabling continuous monitoring, dynamic simulation, and predictive fault detection. Meanwhile, the ERP system provides an integrated environment for maintenance scheduling, data management, and resource allocation, ensuring that maintenance decisions are data-driven and synchronized with operational workflows. Machine learning algorithms, implemented using hybrid physical–data models, predict equipment degradation trends and optimize maintenance interventions. The proposed framework was validated in an industrial-scale composting facility, where results demonstrated a 40% increase in mean time to failure (MTTF), a 35% reduction in repair time, and a 30% decrease in maintenance costs, resulting in a return on investment of 42.5% within the first year. The system’s modular architecture and high adaptability to different machinery types confirm its potential applicability to broader machine design and automation contexts, supporting the transition toward intelligent, self-maintaining industrial systems.