PepsiCo announced last month an initiative with German tech conglomerate Siemens and computer chip maker NVIDIA to create “digital twins” of manufacturing plants and warehouses. The goal is to use AI-backed digital simulation technology to figure out what physical changes to plants and warehouses would best improve speed, quality, and efficiency. According to Siemens, the technology tested in one US Gatorade plant increased throughput by +20% within three months. PepsiCo estimates it could reduce capital expenditures by -10% to -15% by “uncovering hidden capacity and validating investments in a virtual environment” before construction. “This allows the company to optimize existing assets rather than investing in costly new construction,” Siemens said in a blog post about the PepsiCo partnership. BD wanted to understand how digital twins work, so we turned to Niraj Jha, who is the senior director of logistics at Niagara Bottling. His work is focused on how data, automation, and AI are reshaping beverage supply chains. Jha’s team leads large-scale optimization initiatives across Niagara’s national network. Jha has been an outspoken proponent of AI technology in manufacturing and distribution. The following interview has been condensed and edited for clarity: