IMA Digital
into the core of IMA innovation
IMA Digital
IMA Digital is our journey toward smarter manufacturing. We connect data, people, and machines to drive innovation, sustainability, and efficiency across every process – shaping the future of industrial automation.
ARTIFICIAL INTELLIGENCE
Unlocking the Future of Manufacturing with AI at IMA
Driving innovation across every process
At IMA, Artificial Intelligence is not just a tool – it’s a strategic pillar transforming how we design, produce, and deliver advanced automation solutions. From predictive maintenance to intelligent robotics, AI is embedded across our operations to enhance efficiency, quality, and sustainability.
We believe in human-centric automation powered by intelligent systems. AI helps us to:
• optimise production lines through real-time data analysis
• predict equipment failures before they happen
• enhance product quality with machine learning-based inspection
reduce energy consumption and environmental impact
Our AI-Driven Manufacturing Vision
We believe in human-centric automation powered by intelligent systems.
Smart Factories
The algorithms monitor and suggest adjustment production parameters, ensuring maximum uptime and minimal waste.
Predictive Maintenance
Machine learning models analyse sensor data to anticipate failures, reducing downtime and maintenance costs.
Intelligent Packaging
Computer vision and AI-driven robotics enable adaptive packaging solutions tailored to product variability.
Sustainable Manufacturing
AI helps us track and reduce energy usage, optimise resource allocation, and support circular economy initiatives.
AI Advantages
PROCESSES OPTIMISATION
At IMA, we leverage AI to analyse vast volumes of sensor and machine data, enabling us to identify patterns, trends, and anomalies. This data-driven approach empowers us to optimise production processes, pinpoint areas for improvement, and reduce waste.
MAINTENANCE PREDICTION
With the power of AI, we can analyse sensor data to monitor machine performance and accurately predict potential maintenance issues. This proactive maintenance approach allows us to address problems before they occur, minimising machine downtime and maximising overall efficiency.
IMPROVED QUALITY
Our AI-powered system detects product defects or anomalies during production, enabling prompt identification of quality issues and necessary corrective actions for improved product quality.
COSTS REDUCTION
AI plays a crucial role in optimising processes, minimising waste, and preventing costly failures and downtime. Through automation and optimisation, AI enhances operational efficiency, resulting in lower production costs.
ENERGY EFFICIENCY
AI enables us to monitor and analyse energy consumption across production lines in real time. By identifying inefficiencies and suggesting optimal operating parameters, our systems help reduce energy waste and support IMA’s commitment to sustainable manufacturing.
FLEXIBLE AUTOMATION
Through AI-driven adaptive control systems, our machines can automatically adjust to different product types, formats, and production conditions. This flexibility allows for faster changeovers, reduced setup times, and greater responsiveness to market demands.
IMA AI Labs
Exploring the Future of Intelligent Automation at IMA Group
At IMA Group, innovation is driven by a deep commitment to research and collaboration. Our Artificial Intelligence initiatives are spearheaded by two pioneering laboratories:
• IMA AI Lab, dedicated to advancing machine learning and intelligent systems across industrial applications
• Digimech, a joint venture with the University of Bologna, focused on the intersection of digital mechanics and AI.
These labs are shaping the future of smart manufacturing, combining academic excellence with industrial expertise.
IMA Digital is evolving into a fully integrated ecosystem, where advanced technologies such as intelligent monitoring, industrial cybersecurity, Digital Twin solutions, and immersive experiences converge to redefine how we design, manage, and interact with the packaging, process and automation world.
Digital
ADVANCED MONITORING
for Production Efficiency
Remote Monitoring
At IMA Group, advanced remote monitoring is a cornerstone of our commitment to operational excellence and continuous innovation. By integrating cutting-edge industrial sensors, IoT platforms, and predictive models, we enable real-time acquisition, analysis, and interpretation of machine data – empowering automated decision-making and proactive maintenance strategies.
Our Data-Driven Manufacturing Vision
We believe in human-centric automation powered by connected systems.
Industrial IoT & Advanced Sensor Infrastructure
IMA’s production lines are equipped with a robust Industrial IoT (IIoT) architecture that systematically collects process, environmental, and structural data through embedded sensors. Key parameters monitored include:
• vibro-acoustic signals and operating temperatures
• pressure, flow rates, and energy consumption
• machine cycle logic and response times
This data is transmitted to edge or cloud-based systems, ensuring real-time visibility into the operational integrity of each machine and production line.Real-Time Data Fusion & Anomaly Detection
IMA leverages multi-channel data fusion techniques to aggregate heterogeneous datasets, forming the basis for highly reliable diagnostic models. Our AI-powered anomaly detection algorithms – based on unsupervised machine learning and statistical methods – identify deviations from nominal patterns before they escalate into critical failures.
These intelligent systems trigger alerts and initiate corrective actions, transforming reactive maintenance into a predictive and optimized process.Integration with Maintenance & Service Ecosystems
IMA’s remote monitoring systems are fully integrated with digital maintenance platforms, enabling:
• automated work order generation based on predictive alerts
• remote diagnostics by IMA service teams
• historical data tracking for root cause analysis and continuous improvement
This integration ensures faster response times, reduced on-site interventions, and a more sustainable service model.Cybersecurity & Data Governance
Given the critical nature of production data, IMA adopts a security-by-design approach:
• encrypted data transmission across all IoT layers
• role-based access control and secure authentication
• compliance with international standards (e.g., ISO/IEC 27001, GDPR)
This ensures that remote monitoring is not only powerful but also safe and compliant.Custom Dashboards & KPIs
Operators and plant managers benefit from customizable dashboards that provide:
• real-time KPIs on machine health and performance
• visual alerts and trend analysis
• drill-down capabilities for component-level insights
These tools enhance situational awareness and support data-driven decision-making at every level.Scalability & Cross-Platform Compatibility
IMA’s monitoring solutions are designed to be:
• scalable across multiple lines and facilities
• compatible with third-party systems (MES, ERP, CMMS)
• modular, allowing phased implementation based on customer needs
This flexibility ensures that the solution grows with the customer’s digital maturity.
Related Services
Consulting & Analytical Services
IMA Sentinel
A data-driven platform for real-time monitoring and predictive analytics.
Digital
CYBERSECURITY
for Smart Manufacturing Systems
Secure-by-Design Architecture
In an increasingly connected industrial landscape, cybersecurity is a strategic pillar of IMA Group’s approach to digital innovation. Protecting production assets, data flows, and remote monitoring infrastructures is essential to ensure operational continuity, safeguard intellectual property, and maintain customer trust.
Our cyber-safety Manufacturing Vision
We believe in safety-first automation powered by connected systems.
Data Protection & Governance
IMA adopts rigorous data governance policies to ensure the confidentiality, integrity, and availability of production data:
• end-to-end encryption for data in transit and at rest
• role-based access control (RBAC) and multi-factor authentication
• compliance with international standards such as ISO/IEC 27001, NIST, and GDPR.
These measures guarantee that sensitive machine and process data are protected against unauthorized access and manipulation.Threat Detection & Response
Advanced monitoring tools are deployed to detect and respond to cyber threats in real time:
• intrusion detection systems (IDS) and security information and event management (SIEM) platforms
• behavioral analytics to identify anomalies in network traffic and system usage
• automated incident response protocols to contain and mitigate risks swiftly
IMA’s cybersecurity framework ensures that potential threats are identified early and addressed before they impact production.Resilience & Business Continuity
Cybersecurity at IMA is also about resilience – ensuring that systems can recover quickly from disruptions:
• redundant architectures and disaster recovery plans
• regular penetration testing and vulnerability assessments
• cyber drills and training programs for internal teams
These practices reinforce IMA’s commitment to uninterrupted operations and long-term reliability.Customer-Centric Security
IMA collaborates closely with customers to tailor cybersecurity solutions to their specific needs:
• custom security configurations based on plant architecture
• secure remote access for diagnostics and support
• transparent reporting and audit trails for compliance and accountability
By aligning cybersecurity with customer requirements, IMA ensures that digital transformation is both powerful and secure.
Digital
MACHINE VIRTUALISATIONS AND SIMULATIONS
for Smart Manufacturing Systems
Advanced simulations to improve your efficiency
IMA Group is at the forefront of digital transformation in manufacturing, leveraging Digital Twin technology to enhance design, operation, and optimisation of production systems. Through machine virtualisation and plant simulation, we enable a new level of insight, control, and agility across the entire lifecycle of industrial assets.
What is a Digital Twin?
A Digital Twin is a virtual replica of a physical machine or production line, continuously updated with real-time data. It mirrors the behavior, performance, and condition of its physical counterpart, enabling:
•Real-time monitoring and diagnostics
•Predictive maintenance and performance forecasting
•Simulation of operational scenarios and process changes
IMA’s Digital Twin solutions are built on high-fidelity models and integrated with IoT and AI platforms, ensuring accurate and dynamic representation of production systems.
Our virtualisation & simulation Vision
We believe in digital world powered by simulations.
Virtual Commissioning & machine simulation
Before physical deployment, IMA uses virtual commissioning to simulate machine behavior and control logic in a digital environment. This allows:
• early validation of automation sequences
• reduction of commissioning time and cost
• identification of design flaws before production
Machine virtualisation also supports operator training, enabling safe and immersive learning experiences without interrupting live production.Plant-level simulation & optimisation
Beyond individual machines, IMA applies plant-wide simulation to model entire production flows. These simulations help:
• optimise layout and logistics
• test production scenarios and throughput strategies
• evaluate energy consumption and sustainability metrics
This holistic approach supports data-driven decision-making and continuous improvement across manufacturing operations.Integration with monitoring & AI systems
Digital Twins are tightly integrated with IMA’s remote monitoring and AI platforms, enabling:
• closed-loop feedback between physical and virtual systems
• real-time anomaly detection and root cause analysis
• continuous learning and model refinement based on live data
This synergy ensures that Digital Twins evolve with the system, becoming smarter and more predictive over time.Benefits for customers
Implementing Digital Twin and simulation technologies delivers tangible advantages:
• accelerated time-to-market for new machines and lines
• reduced downtime and maintenance costs
• improved product quality and process reliability
• enhanced flexibility in responding to market changes
• sustainable production through optimized resource usageTraining & Human-Machine Interaction
Virtual environments powered by Digital Twins are used for:
• operator training in realistic, risk-free scenarios
• remote assistance and guided troubleshooting
• human-machine interface (HMI) testing and usability optimisation
These applications improve safety, efficiency, and user experience on the shop floor.Sustainability & Resource Optimization
Simulations allow IMA to model and optimize:
• energy consumption
• material usage
• waste reduction strategies
This supports IMA’s commitment to sustainable manufacturing and helps customers meet their ESG goals.
Digital
IMMERSIVE TECHNOLOGIES
for technical training & production simulations
Digital Twins for Technical Training
IMA Group is pioneering the use of immersive technologies -including Virtual Reality (VR), Augmented Reality (AR), and Mixed Reality (MR) – to transform how operators, technicians, and engineers interact with machines and production environments. These tools enhance learning, safety, and efficiency across the entire lifecycle of industrial systems.
Our immersive Manufacturing Vision
We believe in multi-immersive automation powered by virtual systems.
Digital Twins for technical training
By combining Digital Twin models with immersive environments, IMA enables realistic and interactive training experiences:
• virtual replicas of machines and lines simulate real-world behavior
• live data integration allows trainees to interact with systems in real-time
• scenario-based learning supports troubleshooting, maintenance, and operational decision-making.
This approach accelerates skill acquisition and ensures that training is aligned with actual production conditions.Immersive operator training on simulated
Operators can engage in fully immersive training sessions using VR headsets or AR interfaces:
• hands-on practice with machine controls and workflows
• safe simulation of emergency procedures and fault conditions
• gamified learning modules to improve engagement and retention.
These experiences reduce onboarding time, minimize human error, and improve overall plant safety.Remote training & support
IMA’s immersive platforms support remote training and assistance, enabling:
• virtual classrooms for distributed teams
• remote expert guidance via VR overlays and live annotations
• on-demand access to training modules and interactive tutorials.
This flexibility is especially valuable for global operations and decentralized manufacturing networks.AR for maintenance & field operations
AR and VR are used to enhance on-site maintenance and diagnostics:
• step-by-step visual instructions overlaid on physical equipment
• real-time data visualization from sensors and control systems
• remote collaboration with IMA experts for guided interventions.
AR reduces downtime, improves accuracy, and empowers technicians with contextual information.Integration with IoT & real-time data
VR/AR environments are enriched with live data from IMA’s IoT and monitoring systems:
• sensor data overlays for contextual awareness
• dynamic simulations based on actual machine conditions
• predictive insights powered by AI and analytics.
This ensures immersive experiences are not static, but responsive and intelligent.Collaborative & multi-user environments
IMA is developing collaborative immersive spaces where multiple users can:
• interact with the same virtual machine or line
• simulate team-based operations and workflows
• participate in shared training or troubleshooting sessions.
This fosters teamwork, communication, and experiential learning.
Digital Sustainability
Driving sustainability with digital solutions
We are able to analyse the energy impact of products, production stages, and machine configurations, comparing consumption with historical or optimal operating conditions.
Identifying machine stops or components that contribute to a loss in energy efficiency we can support strategies for reducing the CO2 footprint and achieving energy savings.
Collaboration & Open Innovation
Collaboration, co-creation, and open ecosystems
At IMA Group, innovation is not confined within company walls. We believe that the future of manufacturing is shaped through collaboration, co-creation, and open ecosystems. That’s why we actively engage with startups, research centers, universities, technology providers, and customers to accelerate the development of next-generation solutions.
Our collaborative Manufacturing goal
We believe in shaping an innovative automation landscape through research and development.
An ecosystem approach to innovation
IMA fosters a culture of open innovation by building strategic partnerships across the industrial and digital landscape:
• joint R&D projects with academic institutions and research labs
• technology scouting and co-development with startups and scale-ups
• collaborative platforms for sharing knowledge and prototyping new ideas
Customer co-innovation programs to tailor solutions to real-world needs. This ecosystem approach enables faster innovation cycles, greater agility, and more impactful outcomesInnovation hubs & living labs
IMA supports innovation through dedicated spaces and programs:
• innovation hubs where cross-functional teams explore emerging technologies
• living labs for testing and validating solutions in real production environments
• design sprints to foster creativity and rapid prototyping
These initiatives create a dynamic environment where ideas move quickly from concept to implementationPartnerships with academia & research
IMA collaborates with leading universities and research institutions to:
• advance applied research in AI, robotics, materials, and sustainability
• develop talent pipelines through internships, thesis projects, and joint programs
• contribute to scientific publications and industrial standards
These partnerships ensure that IMA remains at the forefront of technological and scientific progress.Benefits of open innovation
By embracing open innovation, IMA achieves:
• Faster time-to-market for new technologies
• Greater adaptability to emerging trends and disruptions
• Access to diverse expertise and perspectives
• Stronger innovation culture across the organization
• Sustainable value creation for all stakeholders
AI LAB
AI Lab and Data Embedded machines
Two new centers of expertise have been created within the organization: the IMA AI LAB and Embedded Machines Data. Their mission is to consolidate and expand the use of AI across several fronts – from integrating intelligent functionalities into machines and plants, to advanced data collection and analysis, to the development of predictive algorithms and advanced tools for support and technical assistance. Special focus will be given to enhancing advanced troubleshooting through intelligent systems capable of anticipating, diagnosing, and resolving anomalies with increasing speed and precision.
DIGIMECH LAB
DIGIMECH LAB
Bridging the gap between academia and industry to foster research, development, and training in cutting-edge technological fields: this is the mission of DIGIMECH – Digital and Mechatronic Research & Innovation for Automated Machinery and Systems, the newly established joint laboratory created through a strategic collaboration between IMA Group and the University of Bologna.
DIGIMECH will focus on six key areas:
• Automation and the design of high-performance, low environmental impact machinery
• Advanced robotics to enhance flexibility and efficiency in production lines
• Mechatronics, integrating mechanical, electronic, and IT systems
• Artificial intelligence and Big Data to analyze and optimize production processes
• Additive manufacturing, advancing industrial 3D printing technologies
• Cybersecurity, to protect digital infrastructures and sensitive corporate data
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IMA is world leader in the design and manufacture of automatic machines for processing and packaging.