Unilever and Accenture deploy 40 AI-powered digital twins to transform global manufacturing

Unilever partners with Accenture to build 40 AI-powered digital twins across manufacturing network

Consumer goods giant Unilever is teaming up with Accenture. They will use AI-powered digital twins in factories worldwide. This initiative aims to boost efficiency and quality. Unilever plans to build over 40 new digital twins in the next 18 months. 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 China Digital 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 play Other 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.

Unilever Scales Digital Twins Across Global Manufacturing Network with Accenture

Unilever to scale the use of AI-enabled digital twins across its global manufacturing network. The next-generation technology will help factories improve quality, boost efficiency and respond more quickly to consumer demand. The multi-year program marks a further step in Unilever's journey to apply pioneering technology across its value chain as the company sets out to shape the future of the consumer goods industry. Digital twins are virtual models of factory equipment and production lines. They use live data from physical systems on the shop floor to monitor and predict how machines and processes perform. By integrating digital twins with AI-enabled insights and agentic capabilities, Unilever is equipping manufacturing teams with advanced tools to identify issues sooner, simulate scenarios faster, and make smarter decisions across the production cycle. Building on digital twins already in use, Unilever plans to expand adoption over the next 18 months by building more than 40 new digital twins, creating a scalable blueprint for global rollout. "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 VP for Digital Business Operations, Unilever. "Through our partnership with Accenture to accelerate digital twins, we are turning innovation into measurable impact to create desirable brands for our 3.7 billion consumers worldwide." "Unilever has long been recognized for its supply chain excellence, and expanding the use of manufacturing digital twins reflects the company's continued focus on both technology and people," said Nicole van Det, CEO Accenture Netherlands and Nordics and global account lead for Unilever. "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. Together, we're setting the benchmark for how industrial AI creates long-lasting value in the consumer goods sector." Accenture is supporting Unilever in deploying industrial AI capabilities that use advanced analytics and AI agents to predict maintenance needs, improve performance, and help teams act faster. As the system learns and employees gain confidence in its accuracy, it can progressively take on certain adjustments automatically, with human oversight. Digital twins delivering impact across Unilever's manufacturing network Digital twins are already delivering tangible benefits across multiple Unilever sites: * Superior quality and improved throughput for personal care: In Raeford, North Carolina, United States, a digital twin powering the production of iconic brands including Dove, Degree, and Axe predicts 95% of process flow restrictions in deodorant stick manufacturing, delivering a 20% reduction in waste and a 10% uplift in capacity. * Lower energy consumption for home care products: In Haldia, India - dedicated to powder detergents such as Surf and Sunlight -- an energy twin optimises fan speeds, temperature setpoints and moisture controls, helping achieve a tangible reduction in thermal energy consumption over two years, supporting delivery towards Unilever's scope 1 and 2 climate target. * Better mayonnaise consistency, less waste: In Poznan, Poland - home to producing such iconic brands as Knorr and Hellmann's -- a digital twin stabilizes viscosity variation in mayonnaise, while reducing minor stoppages by up to 20% and cutting waste by nearly 30%. * Elevating the quality of Dove soap: At Gandhidham, India - one of our largest personal care sites in South Asia -- a digital twin helped reduce quality defects by 30% over four years through real-time control recommendations -- as measured in distribution centers right before the product is delivered to the customer. * Efficient ingredients use, consistent quality: In Cu Chi, Vietnam - where Unilever produces liquid home care products such as OMO laundry detergent -- an intelligent mixer powered by an AI digital twin optimizes raw materials dosing, preventing overuse and delivering 1-2% savings in premium ingredients while maintaining superior product quality. Unilever's operational excellence, efficiency and sustainable growth across its supply chain have been recognized by the World Economic Forum's Global Lighthouse Network, where Unilever holds the highest number of designations in the consumer goods sector.

Unilever plc and Accenture plc Scale AI-Enabled Digital Twins Across Global Manufacturing Network

Unilever plc partnered with Accenture plc to scale the use of AI-enabled digital twins across its global manufacturing network. The next-generation technology will help factories improve quality, boost efficiency and respond more quickly to consumer demand. The multi-year program marks a further step in Unilever?s journey to apply pioneering technology across its value chain as the company sets out to shape the future of the consumer goods industry. Digital twins are virtual models of factory equipment and production lines. They use live data from physical systems on the shop floor to monitor and predict how machines and processes perform. By integrating digital twins with AI-enabled insights and agentic capabilities, Unilever plc is equipping manufacturing teams with advanced tools to identify issues sooner, simulate scenarios faster, and make smarter decisions across the production cycle. Building on digital twins already in use, Unilever plc plans to expand adoption over the next 18 months by building more than 40 new digital twins, creating a scalable blueprint for global rollout. Accenture plc is supporting Unilever plc in deploying industrial AI capabilities that use advanced analytics and AI agents to predict maintenance needs, improve performance, and help teams act faster. As the system learns and employees gain confidence in its accuracy, it can progressively take on certain adjustments automatically, with human oversight. Digital twins are already delivering tangible benefits across multiple Unilever plc sites: Superior quality and improved throughput for personal care: In Raeford, North Carolina, United States, a digital twin powering the production of iconic brands including Dove, Degree, and Axe predicts 95% of process flow restrictions in deodorant stick manufacturing, delivering a 20% reduction in waste and a 10% uplift in capacity. Lower energy consumption for home care products: In Haldia, India ? dedicated to powder detergents such as Surf and Sunlight?an energy twin optimises fan speeds, temperature setpoints and moisture controls, helping achieve a tangible reduction in thermal energy consumption over two years, supporting delivery towards Unilever plc's scope 1 and 2 climate target. Better mayonnaise consistency, less waste: In Poznan, Poland ? home to producing such iconic brands as Knorr and Hellmann?s?a digital twin stabilizes viscosity variation in mayonnaise, while reducing minor stoppages by up to 20% and cutting waste by nearly 30%. Elevating the quality of Dove soap: At Gandhidham, India ? one of the largest personal care sites in South Asia?a digital twin helped reduce quality defects by 30% over four years through real-time control recommendations?as measured in distribution centers right before the product is delivered to the customer. Efficient ingredients use, consistent quality: In Cu Chi, Vietnam ? where Unilever plc produces liquid home care products such as OMO laundry detergent?an intelligent mixer powered by an AI digital twin optimizes raw materials dosing, preventing overuse and delivering 1?2% savings in premium ingredients while maintaining superior product quality. Unilever plc's operational excellence, efficiency and sustainable growth across its supply chain have been recognized by the World Economic Forum?s Global Lighthouse Network, where Unilever plc holds the highest number of designations in the consumer goods sector. Its manufacturing AI partnership with Accenture plc builds on previously announced efforts to scale next-generation technology across business operations, including identifying and testing new AI solutions through the AI Horizon3 Lab in Toronto, Canada.