A growing trend in industrial automation involves retrofitting legacy analog systems with integrated smart valves to support digital twin implementation. This approach, increasingly adopted in sectors such as process manufacturing and machining, enables real-time instrumentation data collection and bi-directional system interaction. These capabilities accelerate predictive maintenance, improve reliability, and streamline automation.
Background
The integration of sensor-equipped valves enables continuous data capture of critical parameters, including position, flow, and operational status. This bridges the gap between legacy analog equipment and modern digital systems. At Valve World Expo 2026, intelligent valves were presented as central to digital twin adoption and virtual commissioning, supporting advanced condition monitoring and adaptive control. According to event materials, these valve systems gather and analyze data, responding autonomously to operational changes.1Digitalisation & Automation -- VALVE WORLD EXPO
Industry standards and modernization frameworks-such as ISO 15926 and the RAMI 4.0 reference architecture-provide structured methods for lifecycle data exchange and interoperability between analog and digital systems.2ISO 15926 These frameworks enable seamless data flows, which are critical to digital twin fidelity and reliability.
Details
A July 2024 mechanical engineering retrofit project-E-KISS-demonstrated energy savings of 29.5 percent by integrating sensor technologies and digital twin models into existing machining coolant systems. The retrofit established a bi-directional connection, allowing the twin to receive real-time data and adjust controls for optimized energy use.3Use Case: How digital twins help save up to 29.5 percent energy in mechanical engineering Adding intelligent controls to existing machinery resulted in annual energy savings of 13,590 kWh and €3,324 per machine.3Use Case: How digital twins help save up to 29.5 percent energy in mechanical engineering
A recent scholarly review published eight months ago concluded that retrofitting legacy systems supports digital twin deployment by virtualizing physical assets for real-time monitoring, modeling, and optimization. The review identified retrofits as key to improving efficiency, flexibility, safety, and aligning with Industry 4.0 requirements.4Enabling Technologies of Industry 4.0 for the Modernization of an Industrial Process Integrated valves, once retrofitted, serve as sensor-driven data nodes that enhance reliability and enable predictive maintenance in hybrid analog-digital environments.
Outlook
As electrification and automation advance, retrofitting with integrated smart valves is expected to become standard in brownfield modernization. Trade events such as Valve World Expo 2026 are likely to promote further adoption by featuring interoperability solutions built on established standards. Ongoing adherence to frameworks like ISO 15926 and RAMI 4.0 will remain vital for deploying digital twins across retrofitted facilities.
