Digital twin technology for allergen-free baked goods manufacturing

Overview

Our digital twin technology revolutionizes the allergen-free baked goods industry by providing a comprehensive simulation of the entire manufacturing process. From ingredient formulation to final packaging, this digital twin enables manufacturers to predict and optimize changes in ingredient swaps, equipment geometry, and process setpoints. This results in enhanced crumb structure, moisture control, and extended shelf life for products such as cupcakes, cookies, and granola. By simulating these variables, the technology significantly reduces production costs and minimizes waste, while ensuring regulatory compliance through validated digital records.

Technical specifications

Key features:

• Physics and data-driven simulation: Models every step in the production line, including dosing, mixing, forming, baking, cooling, frosting, and packaging.
• Soft sensors: Utilizes infrared spectroscopy, inline rheometry, and acoustic sensors to monitor moisture, composition, texture, and volume in real time.
• Ingredient and equipment optimization: Evaluates effects of ingredient substitutes and equipment adjustments on product quality.
• Predictive modeling: Employs machine learning and physics-based models to forecast production outcomes and optimize process parameters.

Technology readiness level

This technology is currently at a Technology Readiness Level (TRL) of 3, indicating it is in the early stages of validation with active development and testing phases planned. Future steps include data integration, sensor calibration, model training, and the deployment of a predictive dashboard for real-time process optimization.