DIGITAL TWINS
VIRTUAL REV OL UTION
THE
Is there a way to boost efficiency, quality and sustainability without touching a single physical line? In this article, Kennedy’s Confection explores how digital twins can help confectionery makers test, optimise and innovate virtually.
C
onfectionery manufacturing has always balanced artistry and engineering. From the delicate tempering of chocolate
to the precise filling of gummies and layered bars, every stage of production requires exacting control. Today, however, producers are facing a new layer of complexity. Consumers expect novel formulations—reduced sugar, plant- based proteins, high fibre, functional gummies—while brands must manage rising ingredient costs, sustainability pressures, and shorter innovation cycles. In response, digital twins—virtual replicas of physical processes, equipment, or entire factories—are emerging as a transformative solution for the sector. Unlike traditional simulations, a digital twin is a living model, continuously
updated with real-time operational data. This allows engineers to test modifications, optimise efficiency, and predict potential failures without risking downtime on the production line. For confectionery, where small variations in temperature, humidity, or moulding speed can have significant effects on texture, flavour, and shelf life, these capabilities are particularly compelling. Analysts predict rapid growth in
industrial digital twin adoption across food and beverage. According to MarketsandMarkets, the digital twin market for food manufacturing is expected to grow at a compound annual growth rate (CAGR) of approximately 38% between 2025 and 2030, driven by demand for efficiency, sustainability, and predictive maintenance.
Within confectionery, this adoption is
still in its early stages but accelerating. Leading multinationals are already investing in high-fidelity simulation platforms, while mid-sized companies are exploring cloud-based digital twins that reduce upfront infrastructure requirements. The technology is also supporting ESG goals: energy efficiency, waste reduction, and sustainability targets can all be modelled and optimised in a virtual environment.
Recipe development and factory design goes virtual The digital twin is not confined to machinery. R&D teams are increasingly using it to model products themselves. Blendhub, a food technology firm, has developed digital twins for product formulations, enabling developers to evaluate ingredient interactions, process changes, and textural outcomes in a virtual setting. For confectionery manufacturers experimenting with high-protein bars, sugar-reduced chocolate, or functional gummies, this capability is invaluable. “Digital twins let us explore recipe
adjustments that might take weeks or months to trial physically,” explains Elena Rojas, Head of Product Innovation at Blendhub. “We can model how ingredients behave under different processing conditions, anticipate texture or flavour changes, and optimise formulations before producing a single batch.” In functional confectionery, where
protein, fibre, and plant-based ingredients can dramatically alter texture and mouthfeel, virtual recipe modelling reduces both trial-and-error and waste. The concept of an industrial metaverse
26 • KENNEDY’S CONFECTION • MARCH 2026
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44
