Additive Manufacturing Technology at PepsiCo: How UltiMaker’s Platform Improves Ergonomics and Safety at Work

Originally published on CADXPERT in cooperation with PepsiCo

Food production must meet strict safety requirements, and when optimizing processes, it is essential to consider current laws and health and safety regulations. At the PepsiCo plant in Święte near Środa Śląska, where popular snacks are produced, 3D printing has become an integral part of streamlining various processes.

By collaborating with CADXPERT and integrating the UltiMaker S7 Pro Bundle 3D printer, PepsiCo optimized certain operations and enhanced workplace safety. This case study explores the impact of 3D printing on the plant's daily operations.

About PepsiCo

PepsiCo is a global leader in the food industry, known for its wide range of products from beverages to snacks. In 2023, the company launched a state-of-the-art production facility in Święte, equipped with five production lines. Popular snack brands such as Lay's and Doritos, among others, are produced there.

The plant is one of the most modern facilities of its kind in Europe and plays a key strategic role in PepsiCo's production. With a strong focus on sustainability and eco-friendly manufacturing, the company relies on advanced technologies like 3D printing to support its growth and efficiency.

The Challenge

Like all food production facilities, the PepsiCo plant in Święte must follow strict Food Safety standards, which can pose challenges for implementing 3D printing. However, the company successfully identified key areas where additive manufacturing could deliver real benefits.

One of the challenges was creating and adapting tools for non-standard operations. Quick solutions were needed without long wait times for external orders. 3D printing enabled faster prototyping and testing of new solutions without relying on external suppliers.

In our plant, we have focused on printing components to make our work easier and to improve safety."

-Sylwester Kucharski, a PepsiCo employee.

Thanks to 3D printing, the company could quickly respond to emerging problems and implement improvements. Such a streamlined process would allow for greater production management flexibility and operator safety.

The Solution

After assessing the plant's requirements, the UltiMaker S7 Pro Bundle emerged as the ideal choice. This compact 3D printer was selected due to:

• Printing precision - allows you to create custom parts with high accuracy.
• Compatible with a wide range of materials - including filaments certified for use in the food industry.
• Automatic material management system - making it easier and faster for operators.

Thanks to the S7 Pro Bundle, PepsiCo was able to start printing tools such as coasters for safely knocking out pins in a potato slicer, tablet holders, washers, and sealing caps for screws or CHEP pallet height gauges. These applications not only improve the ergonomics of work but also allow faster response to production needs.

The UltiMaker S7 Pro Bundle thrived with its ease of use, which is crucial for a company in the early stages of 3D printing implementation. The versatility of UltiMaker's solutions makes it possible to design new solutions without costly investments in traditional manufacturing technologies or complex 3D printing systems.

The Results

The implementation of the UltiMaker S7 Pro Bundle at PepsiCo's Swietem plant has brought tangible benefits:

• Increased operator efficiency - ergonomic handles and stands have made work safer and more comfortable.
• Better quality control - special gauges allow quick testing of reusable pallets.
• Lower costs and greater flexibility - the ability to create components yourself avoids long waiting times for delivery and reduces the expense of buying dedicated parts.

With the 3D printer, we are able to quickly implement solutions to improve ergonomics and safety at work. It's a flexibility that we lacked before.

-Sylvester Kucharski

PepsiCo's experience demonstrates that even in the highly regulated food industry, 3D printing can streamline production. Their successful implementation highlights how the right choice of equipment and materials enables the safe integration of new technologies in food manufacturing.