What was once a perfectly automated Pringles factory just evolved again – into a Digital Enterprise with data-based production. Supercharged with Digital Twins and AI, the factory converts big data into a deeper understanding of its complex processes, driving bigger innovation steps.

Nailing the perfect Pringles chip is getting tougher. Variations in raw materials require careful recipe adjustments to ensure consistent dough quality. Experience used to be their only weapon – now digitalization brings big data to the fight. With a Digital Twin of the dough and AI-driven insights, operators can stabilize the dough like never before and crank line performance into overdrive.

Predicting dough quality with the Digital Twin
Traditional dough making once relied on the instincts of seasoned operators – hands, eyes, and years of experience. But digital transformation changed the game. Now, a network of sensors feeds temperature, humidity, protein levels, and other data into an edge-based AI model from Siemens. The model calculates the ideal dough recipe in real time and adapts to the uncertainties of the raw materials. Operators get precise recommendations, tweak the formulation accordingly, and keep production flowing without the waste, stops, or yield losses that recipe changes used to cause. Today, this Pringles factory is a digital lighthouse that runs on data – predicting dough quality and delivering uninterrupted production with consistent, top-tier chips.

AI optimizes energy efficiency and maintenance
But how do you begin a digital transformation in a factory that’s already perfectly automated? Pringles went straight for the use cases with real, measurable value. The Digital Twin of the dough was just the beginning. Then, as an energy-intensive operation, they boosted efficiency with a Siemens energy management system. They also cut maintenance costs by piloting Siemens’ AI-powered predictive maintenance solution – ditching generic schedules in favor of smart, condition-based recommendations that prevent downtime and keep machines in peak shape. Keeping in mind the larger vision of creating greater transparency and innovation throughout the entire organization, Pringles has already created value from the first steps.

Paving the way to the Industrial Metaverse
With these early wins, the Pringles factory has built the foundations for its Industrial Metaverse. Powered by the Siemens Xcelerator portfolio – with Digital Twins and Industrial AI as the building blocks – Pringles is adding new value-driven use cases and connecting them through a unified Digital Thread. Next up: scaling that Digital Thread across more lines and more sites and seamlessly integrating product, production, R&D and engineering to drive innovation and increase agility. The goal: unlocking a fully networked Industrial Metaverse where every plant shares data, insights, and learnings through a single pane of glass.