BrazilConsumer goods2024 – ongoingUnilever
Predictive control of Hellmann's mayonnaise filling
Unilever reported 50% less overfill giveaway after introducing predictive filling control
Problem
The Hellmann's line at Pouso Alegre adjusted filling from downstream weight checks. Delayed feedback allowed excess mayonnaise into jars and increased material costs.
Approach
Unilever introduced Rockwell Automation's FactoryTalk LogixAI Perfect Fill. Its model used upstream process variables to predict fill quantities before filling and adjust equipment controls.
Results
Takeaway
The change brought process predictions into the filling controls before downstream weighing detected a deviation.
Categories
- Size
- Large enterprise
- Industry
- Consumer goods
- Business function
- Production and quality
- Innovation type
- Process innovation
- AI technology
- Predictive analytics and ML
- Adoption
- Vendor solution
- Evidence
- Company's own claim
Sources
Source summaries
Packaging World covered Unilever's presentation about predictive filling at Pouso Alegre. It reported a 50% reduction in overfill giveaway after the line introduced Rockwell's AI software.
Full details are in the original sources.
