Unilever to build AI-powered digital twins

Consumer goods giant Unilever is partnering with consulting firm Accenture to scale the use of AI-enabled digital twins across its global manufacturing network, as companies increasingly deploy artificial intelligence to improve efficiency, quality and sustainability in factory operations.The multi-year programme will see Unilever build more than 40 new digital twins over the next 18 months, creating a blueprint for wider deployment across its factories worldwide.Also Read: Unilever says it won't miss India's premium boom like it did in ChinaDigital twins are virtual replicas of factory equipment and production lines that use live data from physical systems to monitor, simulate and predict performance.

By combining these models with AI-powered insights and agentic capabilities, Unilever aims to help factory teams identify issues earlier, simulate scenarios faster and make more informed decisions."Scaling AI across our operations isn't just a technological shift, it's a commitment to superior products, sustainability and empowering our teams across our factories," said Adam Raeburn-James, global vice president for digital business operations at Unilever.Accenture said it is helping deploy industrial AI capabilities that use advanced analytics and AI agents to predict maintenance needs, improve performance and assist teams in taking corrective action faster.

Over time, some adjustments could be automated with human oversight as confidence in the system grows.The company said digital twins are already delivering measurable gains across several factories globally.At its Raeford facility in North Carolina, which manufactures brands including Dove, Degree and Axe, a digital twin has helped predict 95% of process flow restrictions in deodorant production, resulting in a 20% reduction in waste and a 10% increase in capacity.In India, Unilever's Haldia factory, which produces Surf and Sunlight detergents, uses an energy twin to optimise fan speeds, temperature settings and moisture controls, reducing thermal energy consumption over two years.

At its Gandhidham plant, one of its largest personal care sites in South Asia, a digital twin helped cut quality defects in Dove soap by 30% over four years.Also Read: Unilever bets on 'super growth assets' to strengthen India playOther applications include reducing waste in mayonnaise production in Poland and optimising ingredient use in Vietnam, where AI-powered systems have delivered savings of 1-2% in premium raw materials while maintaining product quality."Having invested early in AI, the company is setting the standard for pairing advanced tools with smart process design and disciplined execution on the shop floor," said Nicole van Det, CEO of Accenture Netherlands and Nordics and global account lead for Unilever.The partnership builds on Unilever's broader push to integrate AI across its operations, including through its AI Horizon3 Lab in Toronto.

The company has also been recognised by the World Economic Forum's Global Lighthouse Network, where it holds the highest number of designations in the consumer goods sector. ...