As warehouse automation projects grow more complex and timelines get tighter, integrators are searching for ways to reduce risk, accelerate startup, and deliver systems with greater confidence.

Emulation-based commissioning has emerged as one of the most powerful tools for achieving those outcomes.

At Steele Solutions Automation (SSI Automation), emulation has become a cornerstone of our controls delivery process; enabling earlier validation, fewer onsite surprises, and dramatically smoother go-lives.

Read on to learn more about what the process entails and get answers to your questions surrounding how it works.

What Is Emulation-Based Commissioning?

Emulation uses a digital twin, a physics-based virtual model of a warehouse, to simulate system behavior before equipment is installed. It allows controls teams to run the actual PLC/IPC logic against a virtual environment that mimics real-world conditions.

Instead of waiting for mechanical installation and field wiring, engineers can test logic months earlier, reducing schedule compression and fieldside chaos during startup.

“Emulation takes commissioning from a reactive process to a proactive one,” Eli Williams, Director of Sales, Controls, explains. “We validate interlocks, safety, and system flow before the first conveyor ever turns on.”

The Main Benefits of Emulation-Based Commissioning

Emulation delivers measurable value for integrators, end users, and commissioning teams. Here’s what you can expect:

  1. Reduced Commissioning and Debug Time. Issues resolved in the digital twin never reach the site, significantly shortening onsite debug windows.
  2. Higher Quality and System Confidence. Logic, safety, and recovery scenarios are validated before operators ever see the system.
  3. Improved Project Predictability. Early testing creates more accurate schedules and cleaner handoffs.
  4. Earlier Operator Training. Teams can learn system flows before hardware is installed.
  5. Fewer Travel Days and Site Hours. Less onsite troubleshooting = lower cost and happier teams.
  6. Better Experience for Everyone. From integrators to end users, stakeholders gain clarity, visibility, and confidence.

“With emulation, integrators walk into startup with confidence. Instead of discovering issues on the floor, we’ve proactively validated logic, safety, and recovery scenarios. It’s one of the most effective ways to reduce risk and control cost.”  – Eli Williams, Director of Sales, Controls

Frequently Asked Questions about Emulation

As more integrators adopt emulation-based commissioning, questions naturally come up about how it works, what it can (and can’t) replace, and the kind of value it brings to a project.

To help clarify the fundamentals (and address some of the most common misconceptions), we’ve compiled a brief FAQ that breaks down the role of emulation, its benefits, and why it’s becoming a critical tool in modern automation delivery.

Q: Is emulation just a visualization tool?

No. Emulation is a functional test environment, not a graphic representation. It executes real control logic and evaluates real equipment interactions inside the model.

Q: How does emulation-based commissioning work?

Emulation-based commissioning uses a digital twin to test and validate controls before equipment is installed. The process follows a clear sequence:

  • First, engineers build a physics-based digital twin that mirrors the facility or system layout.
  • Real PLC/IPC logic is then connected to that virtual model.
  • Flow, safety, and recovery scenarios are run to confirm how the system behaves.
  • Sequences and interlocks are validated long before crews arrive onsite.
  • Any issues are corrected early, reducing rework and surprises during startup.
  • Finally, pre-validated logic is brought to the facility for a smoother, faster commissioning process.

Q: Does emulation replace onsite commissioning?

Not entirely. Emulation streamlines commissioning, but field engineers still verify wiring, devices, and safety circuits onsite.

Q: Do you need a fully built facility before commissioning controls?

Not with emulation. Controls testing can run in parallel with mechanical installation, reducing total project timelines.

Q: Does emulation help with brownfield upgrades?

Yes. Emulation is especially valuable in active facilities where downtime is limited.

Q: When should integrators use emulation instead of traditional-only commissioning?

Use emulation when timelines are tight, when brownfield upgrades limit downtime, or when multiple vendors must coordinate system behavior early. Emulation resolves issues months before startup, which reduces risk during onsite work.

Why Steele Solutions Automation Leads in Emulation

SSI Automation brings deep controls expertise and a history of working shoulder-to-shoulder with integrators. Many of our engineers have integration backgrounds, which means we understand the pressure of timelines, system complexity, and startup success.

“What really sets Steele Solutions apart in emulation is the depth of our controls expertise and the way we integrate it into the entire project lifecycle,” Williams adds. “ We don’t just run logic in a virtual model—we build accurate, physics-based environments that mirror real-world behavior, so integrators walk into commissioning already 90% of the way there. Our team’s background in integration means we know exactly where projects can get hung up, and emulation lets us eliminate those surprises before anyone steps on site.”

More specifically, Steele Solutions supports integrators by:

  • Developing PLC/IPC logic aligned with their design and architecture
  • Creating standardized code libraries for consistency and maintainability
  • Running thorough emulation testing before arriving on site
  • Navigating legacy controls upgrades with modern platforms
  • Delivering clean, documented, easy-to-support logic

Emulation Key Takeaways

Emulation allows engineering teams to test real PLC/IPC logic inside a digital twin long before equipment is installed. Most logic, safety, and recovery issues are identified and resolved early, which means integrators experience faster startup, fewer onsite surprises, and far more predictable project schedules. Onsite debug time and travel costs drop significantly, and operators can begin training earlier using the virtual system model.

Ready to Explore Emulation for Your Next Controls Project?

SSI Automation can help you streamline commissioning, reduce risk, and deliver controls solutions with confidence.

Our emulation-driven approach gives teams earlier insight, greater predictability, and a smoother path to go-live, no matter the system’s complexity. Contact us to learn more.