DIGITAL TWIN TECHNOLOGY
predict potential issues and avoid them. It allows confectionery manufacturers to build a personalised marketing strategy, and boost consumer satisfaction.
Getting it right
MentorMate went on to point out that ether can also some drawbacks to the use of digital twins. Developing and deploying digital twins is a long, complex, and costly process. and hardware, as well as expertise. Often, companies are inspired by the potential of the technology and are tempted to implement a digital twin of an end-to-end process. However, a better approach would be to start with a small-scale pilot project. Additionally, digital twin technology can also suffer from data-related issues. To work and their operations will deteriorate due to a Despite being a powerful tool for gaining knowledge and visibility into the production process, digital twins remain just that – a tool – that can assist teams to examine, test, and optimise their products and processes in a digital environment. remain with the human.
Reimagined packaging
Encouraged by the successful implementation of digital twins in other manufacturing sectors,
confectionery
producers are now looking at adopting the technology. Mars, for example, collaborated with software company, Ansys, to help it use simulation to reimagine its packaging process using digital technology.
Using
software it was able to perform virtual testing and prototyping on new packaging across its snacking portfolio. This minimised the need for extensive physical testing during the packaging development process and provided useful insights into various aspects of the production phases, including wrapping, drop tests and failure scenarios. Following initial use of the software researchers at Mars reported a reduction in development times of up to 40% through the use of computer modelling and reductions in of approximately 246 tons.
The use of the technology proved to be an important element of the organisation’s ‘Sustainable in a Generation’ plan which demands the use of breakthrough science,
26 Kennedy’s Confection March 2025
innovative thinking and partnerships to push the boundaries of what is possible. “We continue to see the impact and potential of simulation and digital engineering in progressing sustainability initiatives throughout the world,” says Walt Hearn, Senior Vice President of worldwide sales and customer excellence at Ansys. “Mars was able to successfully implement the insights of Ansys simulation to help optimise its design and packaging processes.”
What to automate?
Aldomak is a family run confectionery business based in Scotland,
producing
Scottish tablet, fudge and macaroons. To help its production facilities keep up with its fast-growing product range, the company set out to integrate a degree of automation into its production processes to complement its essentially ‘handmade’ product range. However, with the team at Aldomak being
day-to-day production issues, there was little opportunity for the team to assess the potential impact of changes or enhancements to its manufacturing processes. Happily, it found a solution when it engaged with the National Manufacturing Institute of Scotland (NMIS) which helped it gain a Research & Technology Organisations (RTOs) grant through Innovate UK,. With the help of NMIS it was then possible to create a digital simulation of Aldomak’s fudge production line, using Siemens’ Tecnomatix Plant Simulation software, to support any future decision-making and investment plans. The digital model draws on a range of
data, including the capacity of the existing machinery,
inventory levels, and work
ways of working. Data was gathered using a mixture of information supplied by the business and a 3D scan of the factory using laser technology.
The digital team at NMIS was able to identify potential bottlenecks and explored
various potential scenarios – such as adding Engineers were also able to examine the of both personnel and products within the factory to establish how best to focus efforts to revolved about the need for heavy lifting and transporting products from one area of the factory to another. The simulation software boiling and mixing processes were combined into one station. Of course, this would also strains and injuries. that an investment in boilers with a higher capacity could lead to a potential increase of 43% in throughput per shift, resulting in an extra 260kg of processed fudge, based on the modelled scenario.
The simulation gave Aldomak food for thought when it comes to the changes needed The team was encouraged to think differently, focus on bottlenecks, and explore various ways to increase throughput before considering any major investments.
Commenting on the project, Dario Riccomini, focus is still on our products being handmade, we see great opportunities to use new technology to change the way we work. In recent years our output volumes and revenue have grown, but we are always keen to explore new systems and processes that can aid further expansion. By combining small improvements and targeting our manufacturing capacity, which may lead to new commercial contracts and wholesale orders. introduction to using manufacturing simulation the model, it highlighted the potential impact of collaborating with researchers to take the business and our products to the next level.”
KennedysConfection.com
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