Pringle parent company Kellanova has developed a stackable chip utilizing a digital twin of its dough after a multi-year effort, according to a report by the Wall Street Journal. While major technology firms race to build custom AI processors to power computing infrastructure, the snack food manufacturer spent approximately $5 million and several years mastering precision potato chip manufacturing through specialized machinery and simulation tools.
How Digital Twin Technology Reshapes Snack Manufacturing
Kellanova’s engineering team deployed a digital twin simulation to analyze how dough moves through the factory production line. According to Jan Laenen, a senior director of engineering at Kellanova, speaking to the Wall Street Journal, the process ensures consistent results: “The same crunchiness, the same taste and feel when you open the can.” The simulation isolates mechanical hurdles like broken dough pieces and sticky chips becoming trapped inside fryers.
Did you know? Industrial software provider Siemens implements similar digital twin methods to streamline complex engineering projects, such as building rockets, advanced batteries, and semiconductor microchips.
Comparing Traditional Potato Chips to AI-Assisted Production
Standard potato chip bags typically yield variable shapes, uneven seasoning distribution, and mixed sizes. Pringles established a distinct manufacturing challenge by requiring uniform stackability, prompting the deployment of artificial intelligence and machine simulation to achieve consistency across every single unit.
Frequently Asked Questions
How much did Kellanova spend on its chip manufacturing project?
According to the Wall Street Journal, the parent company spent about $5 million over several years.
What technology was used to fix manufacturing issues?
Engineers created a digital twin of the dough to simulate the production process and identify bottlenecks like broken dough and sticky chips.
Who verified the consistency of the final product?
Jan Laenen, senior director of engineering at Kellanova, confirmed the output maintains identical crunch, taste, and feel.
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