SAS & Unreal Engine Bring Digital Twins to Modern Factories in 2025
SAS & Unreal Engine Bring Digital Twins to Modern Factories in 2025
The factory floor hums with precision, but not in the physical world. At Georgia-Pacific’s Savannah River Mill, a facility producing napkins, paper towels, and toilet tissue, a virtual replica—rendered in photorealistic detail—allows engineers to tweak operations without touching a single machine. This is the promise of digital twins, and SAS, a leader in data analytics, is leveraging Epic Games’ Unreal Engine to bring this technology to life. Announced at SAS Innovate on May 7, 2025, in Orlando, this initiative is optimizing automated guided vehicles (AGVs) and enhancing decision-making in manufacturing.
Digital twins, virtual models that mirror physical systems in real time, are now a reality. By combining SAS’s AI-driven analytics with Unreal Engine’s photorealistic rendering, this initiative creates immersive simulations that allow manufacturers to test scenarios and optimize processes with clarity. “With the help of SAS and Unreal Engine, we can create realistic simulations of factory operations,” says Roshan Shah, Vice President of AI & Products at Georgia-Pacific. “Imagine watching AGVs navigate through a bustling factory floor, reacting to proximity alerts, obstacles, and rare adverse events in real time.”
The Technology Powering the Transformation
At the heart of this innovation lies the synergy of SAS’s data-crunching expertise and Epic Games’ visually stunning Unreal Engine. SAS’s software suite, including its flagship SAS Viya platform, processes massive datasets from factory sensors and operations, turning raw numbers into actionable insights. Unreal Engine, known for powering Fortnite and Hollywood-grade visual effects, brings these insights to life with real-time 3D visualizations.
The process begins with RealityScan, an Epic Games mobile app that captures photorealistic visuals. RealityScan was used to generate photorealistic visuals of the Savannah River Mill, which were then imported into Unreal Engine for simulation. These assets power advanced simulations using dynamic lighting, real-time physics, and detailed surface rendering—creating a living digital environment for experimentation. SAS’s analytics overlay this environment with real-time data, enabling simulations that predict how AGVs and production lines perform under varying conditions.
The result is a digital twin that enhances factory operations. Georgia-Pacific used the technology to simulate AGV performance and refine deployment strategies, reducing the need for costly trial-and-error testing in live environments. “The powerful analysis and photorealistic simulations delivered by SAS’s enhanced digital twins can enable decision-making and boost output at Savannah River Mill,” Shah notes, highlighting the potential for broader application across Georgia-Pacific’s 150 global facilities.
Beyond Efficiency: Safety and Accessibility
The implications of this technology extend beyond operational efficiency. By simulating human movements alongside AGVs, Georgia-Pacific can evaluate factory layouts to minimize workplace injuries, incorporating environmental and operational variables—a critical concern in an industry where safety incidents carry significant costs. “Adding digital humans into the mix helped us evaluate the factory layout and avoid injuries to real people,” Shah explains.
The partnership also emphasizes accessibility, making advanced analytics available to frontline workers, engineers, and machine operators, not just data scientists. Bill Clifford, Vice President and General Manager of Unreal Engine at Epic Games, underscores this impact: “SAS is opening the door for manufacturers to bring complex data and automated systems to life through 3D visuals. This will make high-fidelity, interactive digital twins more accessible so manufacturers can upgrade their operations, gain better real-time insights, and save money.”
A Cultural Shift in Manufacturing
This collaboration also appeals to a new generation of workers. As manufacturers face labor shortages and an aging workforce, attracting tech-savvy talent is critical. Bryan Harris, SAS’s Chief Technology Officer, sees gaming technology as a bridge to this demographic. “As manufacturers hire the next generation of workers, they need to make the use of data and AI more engaging and appealing,” he says. “Gaming technology—for a generation that grew up playing video games—is one important way to transform business decision-making from charts and spreadsheets to immersive experiences with amazing visual fidelity.”
By integrating game-like interfaces, digital twins make repetitive tasks more engaging, potentially boosting productivity. A machine operator, for instance, can interact with a 3D simulation to test workflows, turning routine tasks into dynamic problem-solving exercises. This approach aligns with the industry’s need to modernize and attract younger talent.
The Ripple Effect Across Industries
While manufacturing is the immediate focus, SAS is exploring broader applications for digital twins. SAS is investigating potential uses in healthcare and urban planning, where digital twins could simulate patient flows or sustainable city designs—though these use cases remain in early stages and are not yet implemented. These broader applications suggest the technology’s versatility, confirmed by SAS’s stated plans to expand beyond manufacturing.
Unreal Challenge use but A New Blueprint for Progress
While Unreal Engine’s high-fidelity visuals enhance digital twins, as seen in Georgia-Pacific’s Savannah River Mill, it has notable drawbacks. Its computational intensity demands powerful hardware, with even basic projects consuming significant resources, potentially straining factory budgets. The engine’s lack of native web-based support complicates remote access for real-time dashboards, requiring costly workarounds. Features like Lumen for dynamic lighting are resource-heavy, risking performance issues without expert optimization. Additionally, its complex C++ codebase and sparse documentation create a steep learning curve, potentially delaying implementation in manufacturing settings. These challenges demand careful consideration for resource-constrained or web-reliant industrial applications.
However, SAS’s use of Epic Games’ Unreal Engine is a technological leap and a vision for smarter, safer manufacturing. At Georgia-Pacific’s Savannah River Mill, a digital twin is not just a tool—it’s a step toward a more efficient and safer future. As SAS expands this technology to other manufacturers, the factory floor is becoming virtual, and the possibilities are vast.
More info here -Have a story? Address it to “the Editor” here
Disclaimer
The information provided in this article is for general informational purposes only and from publicly available sources. While we strive for accuracy, we do not make any representations or warranties, express or implied, regarding the completeness, reliability, or validity of the content. This article does not make any direct claims about specific companies, individuals, or organizations. Any references to reports or external sources are for context and do not imply endorsement or verification of any specific allegations. Readers are encouraged to conduct their own research and seek professional advice before making business decisions. We disclaim any liability for any losses or damages incurred as a result of reliance on the information provided.