Unilever is leveraging the power of 3D printing technology to fine-tune its size scaling and packaging strategies, allowing for a more efficient production process tailored to consumer needs.
In line with emerging consumer preferences for portion-controlled snacks, Unilever is exploring innovative micro-formats for its products. The company is employing cutting-edge technologies, including artificial intelligence and robotics, to enhance various stages of product development and manufacturing.
As the sixth-largest publicly traded consumer goods company worldwide, Unilever encountered significant challenges in replicating the taste and texture of its traditional ice cream offerings while developing bite-sized alternatives, notably the Magnum Bon Bon line. The company emphasized that simply reducing the size of production processes was not a viable solution, as highlighted in a recent blog post.
Developing Grab-and-Go Ice Cream
For the Magnum Bon Bon range, ensuring good coverage of chocolate was paramount, especially since consumers would be handling the ice cream directly rather than using the conventional ice cream stick. R&D teams faced the critical task of preventing the ice cream from melting too quickly, all while aiming to accelerate production and create a product that features a cold core enveloped in warm chocolate.
Temperature Patents: In November, Unilever granted a free non-exclusive license for 12 of its reformulation patents, enabling ice cream manufacturers to utilize valuable insights gained from two pilot programs where Unilever maintained product stability at elevated freezer temperatures.
To address these challenges creatively, Unilever tapped into its advanced prototype engineering center and cutting-edge manufacturing facilities situated at its R&D hub in Colworth, U.K., where automation, robotics, computer-aided design and manufacturing, and 3D printing play pivotal roles in product testing.
“Together with our supply chain teams, we developed some very sophisticated systems to ensure ice cream, sauce, coating, and inclusions are dosed at the correct weight, volume, and temperature to give consistent product architecture and experience,” said Paul Sherwood, who serves as Unilever’s lead R&D process engineer.
– What steps is Unilever taking to address consumer demands for sustainability in their new product innovations?
**Interview with Anna Mitchell, Innovation Lead at Unilever**
**Editor**: Welcome, Anna! It’s great to have you here to discuss Unilever’s exciting innovations in packaging and product development. To start, can you explain how 3D printing technology is shaping Unilever’s production process?
**Anna Mitchell**: Thank you for having me! 3D printing is revolutionizing how we approach packaging and product design. By using this technology, we’re able to rapidly prototype new packaging solutions that are not only more efficient but tailored to meet consumer needs. It allows us to scale production in a way that was previously unachievable, ensuring we can deliver our products more efficiently and responsively.
**Editor**: That sounds impressive! Could you elaborate on how these innovations are aligned with emerging consumer preferences, particularly regarding portion-controlled snacks?
**Anna Mitchell**: Absolutely. Today’s consumers are increasingly looking for convenience and portion control. In response, we’re exploring innovative micro-formats for our snacks, which cater to these preferences. By leveraging AI and robotics alongside 3D printing, we can design and manufacture these new product formats more quickly and effectively, ensuring we respond to market trends in real-time.
**Editor**: It’s fascinating how technology shapes product development. We’ve heard that Unilever faced challenges in replicating the taste and texture of traditional ice cream. How is the company tackling these challenges?
**Anna Mitchell**: Indeed, replicating the sensory experience of traditional ice cream can be challenging, especially when we’re looking to innovate. We’re using advanced technologies, including data analytics and machine learning, to understand consumer preferences better. This helps us refine our recipes and production processes to ensure that even our new formats maintain the quality and taste our consumers expect.
**Editor**: That’s a significant undertaking! Looking to the future, what can we expect from Unilever in terms of sustainability and innovation?
**Anna Mitchell**: Sustainability is at the heart of everything we do. As we innovate, we are committed to reducing our environmental impact, both in the materials we use for packaging and the energy efficiency of our production methods. We believe that integrating sustainable practices with innovative technologies will not only meet consumer expectations but also contribute positively to the planet.
**Editor**: Thank you, Anna! It’s clear Unilever is paving the way for the future of consumer goods. We look forward to seeing how your innovations develop and impact the market.
**Anna Mitchell**: Thank you! It’s an exciting time for us, and we can’t wait to share more with our consumers.
