How digital twins help shipowners cut costs and meet emissions targets

DIGITAL twins are virtual representations of physical ships that continuously mirror a vessel’s hull and engine interactions and fuel use, by ingesting real-time sensor data.

They give operators a live dashboard of performance parameters and even allow risk-free “what-if” scenarios to test changes without endangering the actual ship. The benefits of this real-time vessel monitoring are far-reaching.

OpenOcean STUDIO, a fleet management platform, created by the industry, for the industry, leverages digital twins to deliver accurate performance predictions that support service planning and charter negotiations. By continuously tracking the condition of a ship’s hull and engines, the platform provides insight into when and how to clean each vessel.

The risk-free “what-if” planning also provides a reliable foundation for optimising route planning and estimating fuel consumption. Together, these tools uncover hidden inefficiencies, helping operators reduce fuel use and cut associated emissions.

According to Tom Melamed, head of data science at 90POE: “A digital twin is essentially a virtual copy of a ship that can be used to simulate real life and crucially other possible options. It shows exactly how the vessel’s hull, engine and fuel use are performing and what is contributing to her current consumption. This means operators can see, with absolute clarity, how changes like adjusting speed or optimising a route will play out before they actually happen”

From data to decisions

Crucially, digital twins also play a vital role in supporting regulatory compliance. By continuously tracking fuel consumption and voyage performance, they help demonstrate adherence to IMO emissions regulations and carbon intensity targets.

As highlighted in a paper recently presented by 90POE at HullPIC 2025, a key conference driving discussions on the future of clean shipping, this process leads to “a smarter, more responsive approach to vessel performance management,” where efficiency gains become both visible and measurable.

Using the performance and speed-fuel models, a vessel operator can optimise speed and route to minimise fuel consumption, while meeting the desired ETA. OpenOcean STUDIO’s analytics draw on historical data and weather forecasts to refine voyage plans, effectively lowering CO2 emissions. Fleet managers gain immediate insight into how changes, like an extra knot of speed or an extra tonne of cargo, impact fuel use.

This kind of real-time emissions tracking is increasingly critical as environmental regulations tighten and operators must meet targets such as the IMO Carbon Intensity Indicator. By continuously calculating a vessel’s carbon efficiency, the digital twin helps ensure voyages comply with these standards while still achieving commercial goals.

Managing risk in real time

Beyond fuel and emissions, digital twins improve overall risk management. With up-to-date data on engine and hull condition, companies can better anticipate maintenance needs and avoid costly downtime. They can simulate scenarios, such as the impact of bad weather or additional cargo, helping crews plan for contingencies.

In effect, digital twins reduce uncertainty in shipping operations, turning potential risks into planned, proactive action. Dr. Christos Gkerekos, senior data scientist at 90POE, emphasises: “Digital twins transform vessel operations from reactive to proactive. They let operators model alternative routes and operational profiles, quantify fuel and emissions impacts before committing, and optimise maintenance scheduling. The actionable intelligence it delivers enables tighter cost control, ensures regulatory compliance and maximises vessel availability, making fleets more efficient, competitive and sustainable."

Moreover, with a cloud-based platform, shore teams see the same information as the crew, strengthening safety and decision-making across the organisation. In practice, the OpenOcean STUDIO platform delivers these benefits through intuitive dashboards and alerts. Operators get clear, data-driven guidance, such as recommending the optimal speed based on current fuel prices, rather than relying on raw log data.

Among the main benefits of this technology is its ability to identify propulsion inefficiencies and track improvements in real time, leading to measurable fuel and cost savings. Over time, this leads to a more efficient and sustainable operation, where maintenance is planned, rather than reactive, and emissions are tracked on every voyage.

The digital twin is moving beyond the tech labs into modern shipping. For ship operators interested in exploring the potential of digital twins, 90POE is offering demonstrations of OpenOcean STUDIO. To see how real-time monitoring, predictive maintenance and emissions tracking can streamline operations, readers are invited to book a demo and experience the benefits firsthand.