DIGF-DIRF-06709-Fudge Manufacturing Process Simulation

Industry collaboration project with a Glasgow-based confectionery manufacturer, to develop a digital simulation model of their fudge production line using Siemens Tecnomatix Plant Simulation software. The project employed advanced 3D laser scanning technology and digital twin methodology to identify production bottlenecks and optimise manufacturing workflows. Through comprehensive 'what-if' scenario analysis, the research identified potential for 43% throughput increase and 20% reduction in manual handling requirements. The work demonstrates practical application of Industry 4.0 simulation technologies in small-scale manufacturing environments, bridging academic research with real-world industrial challenges.

The research team helped a Scottish sweet-making company improve their factory efficiency by creating a computer model of their production line. Using advanced 3D scanning and simulation software, the researchers identified where bottlenecks were slowing down production and found ways to make 43% more sweets per shift. This project demonstrates how digital technology can help small manufacturers become more efficient without major investments, and shows the value of university expertise in solving real business problems.

The digital simulation revealed significant optimisation opportunities in Aldomak's fudge production line. Key findings included: potential for 43% throughput increase through higher-capacity boilers; 20% reduction in manual handling by combining boiling and mixing processes; identification of workflow bottlenecks limiting production capacity; and validation of digital twin methodology for small-scale manufacturing environments. The project demonstrated the practical value of Industry 4.0 simulation technologies for SME manufacturers seeking evidence-based investment decisions.

Project funded through UKRI Innovation Voucher scheme (£15,000). Featured as NMIS case study demonstrating successful knowledge exchange between academia and industry. Results inform ongoing research into digital manufacturing solutions for small and medium enterprises.