operations, shifting from a reactive to a predictive, data-driven approach. Collaborating with Fractal, the company deployed AI-powered packaging technology that continuously tracks production metrics and automatically adjusts key parameters in real time. This allows PepsiCo to maximize throughput, reduce waste, and improve efficiency, all without manual intervention.
The system not only boosts performance but also enhances sustainability and ROI.“ What we’ re helping PepsiCo do right now is to drive better asset utilization by increasing throughput, reducing wastage, and lowering electricity consumption,” adds Pranay Agrawal.
Through this collaboration, PepsiCo is transforming packaging from a manual process into an intelligent, self-learning system, setting a new benchmark for smart manufacturing.
Road Ahead: Scaling innovation globally
Following a successful pilot, PepsiCo has scaled the smart packaging solution across multiple sites in Latin America and is now expanding globally. Once proven effective on individual lines, the system can be replicated across PepsiCo’ s vast manufacturing network, unlocking efficiency and consistency at scale. broader AI-driven digital transformation.“ From farming to snacking at your table, we leverage AI across the entire value chain,” explains Venky Santhirahasan,“ from potato seed planning to demand forecasting, supply planning, manufacturing, transportation, network optimization, and how we effectively deliver our product.”
Future developments could extend into areas including material consumption monitoring, energy usage optimization, machinery maintenance prediction, and transportation logistics, continuing PepsiCo’ s journey toward a smarter, more sustainable manufacturing ecosystem.
“ Now, our packaging line can self-optimize and adjust the bags per minute automatically. That results in increased throughput, reduced waste, and optimized cost.”
— Venky Santhirahasan SVP of Engineering at PepsiCo
“ The beauty of this is that if it works on a few lines, we can scale it globally,” says Pranay Agrawal. The collaboration also extends beyond packaging to PepsiCo’ s
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