Unilever expands digital twin programme with Accenture

The rollout forms part of the company’s broader strategy to scale artificial intelligence and advanced analytics across its operations

Unilever is extending the use of digital twin technology across its manufacturing network through an expanded partnership with Accenture, with more than 40 digital twins expected to become operational over the next 18 months.

The rollout forms part of the company’s broader strategy to scale artificial intelligence and advanced analytics across its operations, with the technology designed to help manufacturing teams improve efficiency, quality and decision-making.

Digital twins to support factory operations

A digital twin is a virtual replica of a physical asset or process that uses live data to simulate, predict and optimise performance.

Under the expanded programme, Unilever will deploy AI-enabled digital twins and emerging agentic technologies across its factory network. The company said the systems will help teams identify issues earlier, model scenarios more quickly and make more informed decisions throughout the production cycle.

Expansion builds on existing AI strategy

The initiative follows Unilever’s wider investment in artificial intelligence, including the establishment of its AI Horizon3 Lab in Toronto, where the company explores and tests emerging AI applications.

Adam Raeburn-James, Global VP for Digital Business Operations at 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."

The technology is intended to create a framework that can be scaled globally across manufacturing operations.

Personal Care sites report efficiency gains

Unilever said digital twins are already delivering measurable results across several manufacturing sites.

At the company’s Raeford facility in North Carolina, which produces brands including Dove, Degree and Axe, a digital twin was able to predict 95 per cent of process flow restrictions in deodorant stick production. According to Unilever, this contributed to a 20 per cent reduction in waste and a 10 per cent increase in production capacity.

At the Gandhidham site in India, one of Unilever’s largest Personal Care facilities in South Asia, digital twin technology helped reduce quality defects in Dove soap production by 30 per cent over four years through real-time process recommendations.

Home Care operations improve resource efficiency

The technology has also been applied across Home Care manufacturing.

At the Củ Chi plant in Vietnam, which produces liquid home care products including OMO laundry detergent, an AI-powered digital twin was used to optimise raw material dosing. Unilever reported savings of between 1 and 2 per cent in premium ingredients while maintaining product quality.

Meanwhile, at the Haldia facility in India, digital twin technology has been used to optimise energy consumption in the production of powder detergents such as Surf and Sunlight. The system adjusts factors including fan speeds, temperature settings and moisture controls to improve efficiency.

Technology supports sustainability goals

Unilever said the deployment of digital twins is helping support its environmental targets by reducing waste and improving energy efficiency across manufacturing operations.

The company has committed to reducing absolute operational greenhouse gas emissions from Scope 1 and Scope 2 sources by 100 per cent by 2030, compared with a 2015 baseline.

Accenture highlights industrial AI potential

Nicole van Det, CEO, Netherlands and Nordics, Accenture: "Having invested early in AI, Unilever 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 measurable value in the consumer goods sector."

The rollout comes as manufacturers increasingly explore AI-driven technologies to improve operational performance and build more responsive production networks.

Adam Raeburn-James: "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."

www.unilever.com

www.accenture.com

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