The Uses of Realistic Simulation for Consumer-Packaged Goods & Retail

Both during and following the pandemic, uncertainty and unpredictability has hampered businesses across the globe. This is particularly problematic within the consumer-packaged goods (CPG) sector.

In order to be competitive in the present environment, and bring better products to market more quickly, all while cutting costs, many organizations are confronting an urgent need to simplify their product innovation processes.

To do this, companies in the CPG sector need to go through a digital transformation that comprises a comprehensive approach that addresses production, performance, and product.

This is where simulation comes in.

Simulate the perfect package

An effective way to comprehend and analyze the specifics of intricate product processes is through simulation.

The other options include depending too much on trial and error or overcompensating with substances or procedures that could put a business’s capacity to deliver the greatest product at risk.

Instead of employing physical testing, engineers can test many more design possibilities and obtain significantly more insight by simulating the behavior of ingredients as they interact with processing equipment and each other using digital twin physics-based simulation.

Consequently, it is possible to optimize materials processing while adhering to quality and regulatory standards, enabling the production of customized, superior products that satisfy a range of customer needs.

How can the SIMULIA help the Consumer-Packaged Goods Industry?

SIMULIA’s realistic simulation applications for Consumer-Packaged Goods manufacturers can support across the entire product lifecycle, and across a range of functions.

Common uses include:

  • Blow Molding simulation: Shape is optimized to yield the intended ultimate thickness distribution
  • Conveying: Minimizes damage by guaranteeing that bottles won’t fall off the production line or become trapped
  • Filling simulation: Calculates the filled volume and forecasts the behavior of the packaging after the product is filled
  • Capping: Calculates the torque needed to open and close the cp while preserving the integrity of the seal
  • Labeling: Forecasts if a new bottle design will result in the label shredding or creasing
  • Casing: Predicts final product form in shrink wrap and whether the casing can maintain shape after handling, reducing shipping damage
  • Palleting simulation: Estimates bottle behavior based on top-load (weight) in a pallet, hence reducing bottle breakage

Key Benefits of Simulation in the Consumer-Packaged Goods Industry

Cost savings

In order to cut costs for CPG companies, simulation is essential. Not only can it do away with the necessity for expensive and frequently ineffective physical prototypes, but it is also able to validate and optimize targeted cost-cutting measures like altering the product’s design or packaging.

By applying real-world circumstances to virtual models, designers may test different configurations and combinations of materials far more efficiently than they could with physical prototypes and trial and error.


Consumers of today are placing a higher value on the environment and are becoming more prepared to forgo their preferred brands and goods in favor of more environmentally friendly options.

A design’s waste and emissions, materials that can be recycled, and whether or not sustainable materials will serve the same purpose as non-sustainable ones can all be predicted using simulation.

Simulation helps companies evaluate a variety of sustainable designs and speeds up the process of introducing new packaging to the market while reducing physical waste, all while eschewing trial-and-error prototypes.

Quicker time-to-market

With the correct digital tools, it is possible to test thousands of design variations in parallel, enabling CPG companies to speed up the time it takes them to get improved designs into production. Compared with traditional approaches, simulation allows companies to optimize their products all in one go, getting their products on the market in a fraction of the time.

Enhanced customer experience

The era of unwavering brand loyalty is long gone. These days, rival items that offer a superior experience can easily win over customers, and packaging design is now just as significant as the product itself.

For instance, food and beverage companies that offer packaged goods need to continuously enhance design in order to stay competitive. A product that drips, dispenses too slowly or too rapidly, or has a bottle that is just too hefty might all deter a customer from buying it.

Get in touch

With SIMULIA, you can make virtual testing and analysis a standard business practice, helping you to reduce errors and accelerate innovation. Get in touch today to find out how you can leverage realistic simulation for consumer-packaged goods and retail to optimize your production processes.