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The Sweet Side of Simulation Behind the Scenes at Nestlé
Technology Category
- Analytics & Modeling - Predictive Analytics
- Analytics & Modeling - Real Time Analytics
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Food & Beverage
Applicable Functions
- Product Research & Development
- Quality Assurance
Use Cases
- Predictive Quality Analytics
- Machine Condition Monitoring
- Process Control & Optimization
Services
- Software Design & Engineering Services
- System Integration
The Challenge
Ensuring the consistency and quality of chocolate bars, wafers, and cereals is a significant challenge for Nestlé. For chocolate bars, the flow rate and pressure of the chocolate exiting each nozzle must be consistent to ensure uniform weight and nutritional content. For wafers, uneven heating during baking can cause different moisture concentrations, affecting texture and potentially causing spontaneous snapping. For cereals, the high-temperature extruder must maintain consistent pressure and friction to cook the dough evenly, and the viscometer housing must withstand high pressure to ensure consistent dough quality.
About The Customer
Nestlé is a global food and beverage leader, renowned for its wide range of products including chocolates, cereals, and wafers. The company operates a Product Technology Centre in York, UK, where engineers focus on the research and development of confectionery products. Nestlé is committed to delivering high-quality, safe, and nutritious products to its customers. The company employs advanced simulation tools to optimize its manufacturing processes, ensuring consistency, efficiency, and adherence to nutritional standards. Nestlé's dedication to innovation and quality makes it a trusted name in households worldwide.
The Solution
Nestlé employs a combination of modeling and simulation tools to optimize its production processes. For chocolate bars, the company uses SOLIDWORKS for design and COMSOL Multiphysics for simulation to ensure uniform flow rate and pressure across all nozzle tips. This helps maintain consistent weight and nutritional content. For wafers, simulation is used to optimize the baking plate design by analyzing the flow of hot air and ensuring even temperature distribution. This reduces fuel consumption and improves wafer quality. For cereals, Nestlé uses simulation to design a viscometer housing that can withstand high pressure within the extruder, ensuring consistent dough quality and even cooking.
Operational Impact
Quantitative Benefit
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