Close the loop: how Industry 4.0 is aiding sustainable material development

Sustainability in today’s context goes beyond merely recyclable packaging, it includes every facet of the supply chain. However, many CPG packaging manufacturers struggle with siloed departments, costly working processes and the complex packaging ecosystem, which includes materials suppliers, converters, printers, co-packers and retailers. Working with different stakeholders across different geographies can result in multiple iteration loops and delays in getting packaging designs to market.

“Manufacturing has traditionally been a siloed and outdated industry, resistant to change and the infiltration of digital technologies to reinvigorate it,” confirms Bailey. “However, we are starting to see the sector slowly adopt new technologies such as AI and machine learning for innovation.

“This is important as we enter the fourth industrial revolution, as they are now in a race to keep at pace with the increasingly changing demands of businesses and consumers.”

To achieve authentic end-to-end sustainability, from sourcing to the post-consumption experience, CPG packaging manufacturers must eschew entrenched, linear working processes, in favour of a more flexible, data-driven approach to their packaging design and development, as Bailey explains.

“Typically, CPG packaging supply chains consist of too much stock, the wrong materials and other unutilised products, which could all be solved by implementing a virtual supply chain,” he says.

“For manufacturing companies to thrive, workers must be given the opportunity to create and collaborate, to implement ideas and make knowledgeable decisions.

“Adopting and utilising a virtual twin for all aspects of a CPG business end-to-end and across the entire value chain is fast becoming a pre-requisite to operate successfully in the market. In-silico, first for package design and simulation, is simply one component and discipline that is required.

“Implementing a fully virtual supply chain means that businesses can ensure it is optimised and as sustainable as possible from package design to delivery to the store or the consumer’s home.”

Dassault Systemes' 3DEXPERIENCE platform provides a virtual environment, collaborative tools and solutions that enables CPG packaging manufacturers to ‘close the loop’ for sustainable packaging.

Key characteristics include a 3D designing solution that allows industrial customers to reducing the number of physical prototypes and realise substantial savings in product development cycle times.

“3DEXPERIENCE allows manufacturers to have a holistic overview of designing products, from concept right through to the physical product,” Bailey explains. “Virtual prototyping and simulation tools mean that all aspects of packaging can be designed and shared with various stakeholders, in a virtual environment. Changes can be tracked and amended without barriers of time or location.

“Using a virtual environment to design means that packaging manufacturers can reduce the cost and waste of physical prototypes and keep track of the materials used in the creation of the product.”

CPG packaging manufacturers can create a 3D model of the packaging design in a real-world setting, review and enhance it quickly and easily, and use 3D simulation to ensure that the packaging holds up throughout its entire lifecycle.

The 3DEXPERIENCE platform also allows businesses to construct and compare different material compositions to determine the best option for sustainable packaging, and choose the best trade-offs in order to balance materials and inventory.

Consumer expectations and intense competition within the CPG space means that sustainable packaging must also maintain high standards of quality, cost and ease of use. Again, 3DEXPERIENCE can help.

“Manufacturers can use the tool to source the optimum materials for products that meet the packaging needs, as well as expectations, of the modern-day consumer,” says Bailey.

“3DEXPERIENCE provides business and people with virtual universes to imagine sustainable innovations. Its collaborative solutions transform the way products are designed, produced, and supported, fostering social innovation and expanding possibilities for the virtual world to improve the real world.”

Bailey believes the flexibility to adapt quickly to new consumer trends in a world where industry compliance and regulation will only increase could be a key differentiator, and that the only way for CPG packaging manufacturers to address all these challenges is by digitising the entire supply chain.

“This is particularly true for large organisations who are competing more and more with smaller niche players who are quick to satisfy the latest consumer demands,” he says. “Solutions like the 3DEXPERIENCE platform empower businesses and their manufacturers to innovate swiftly and more sustainably than before.”

So, for CPG packaging manufacturers to thrive in an increasingly competitive market, they must be closely attuned to consumer trends, and have the flexibility to create sustainable, bespoke packages that are cost effective, easy to use, respect the environment and deliver designs consumers will love.

“Businesses today must look beyond the aesthetics of a product or the practicalities of a service, as consumer engagement and loyalty count far more than features and benefits alone,” says Bailey.

“Customers want unique, personalised experiences and by fusing people, ideas and data to capture insights and expertise, it is possible for businesses to offer them this.”