Creating Magnum’s new Bon Bons—bite-sized ice creams packed with the same indulgence as the full-sized originals—required cutting-edge research and development. Leveraging robotics and AI, the production process was streamlined to bring these shareable treats to market quickly and efficiently.
From Concept to Market: The Innovation Journey
- Prototyping with Precision: Using 3D printing, Magnum’s R&D team developed prototypes to determine the ideal Bon Bon size for optimal packing and transportation.
- Chocolate Waterfall Technology: A specially engineered system coats thousands of bites per minute with Magnum’s signature cracking chocolate while minimizing waste.
- Automated Production Lines: Sophisticated robotics enable the manufacture of over 200 million Bon Bons annually, ensuring consistency and quality at scale.
Magnum Bon Bons: A Premium Indulgence
The new Bon Bons, packaged in 12-piece shareable tubs, cater to consumer demand for portion-controlled treats. With Gen Z driving trends in snacking and flavor exploration—90% of this demographic snacks daily—the bite-sized format provides a perfect match for their preferences.
Perfecting Magnum’s Signature Taste and Texture
Crafting the Bon Bons required overcoming challenges unique to miniaturized products:
- Preserving Core Qualities: Replicating Magnum’s creamy texture and signature chocolate coating in a smaller format demanded a reimagining of traditional production processes.
- Hand-Friendly Design: Unlike stick-based ice creams, Bon Bons are designed to be enjoyed directly from the tub, necessitating a formulation that resists melting quickly.
- Enhanced Indulgence: Each bite includes ribbons of sauce for a multi-layered sensory experience.
Advanced Facilities Driving Innovation
Unilever’s Advanced Prototype Engineering Centre and Advanced Manufacturing Centre in Colworth, UK, played a crucial role in the Bon Bons’ development:
- Cutting-Edge Tools: Computer-aided design (CAD), 3D printing, and small-scale manufacturing equipment enabled precise testing and refinement.
- Efficient Production: Pilot-scale runs minimized waste and optimized full-scale production processes.
A Game-Changer in Ice Cream Production
The development process also introduced a new chocolate enrobing technique. Unlike traditional dipping, this method involves passing ice cream pieces through a continuous ‘chocolate waterfall,’ ensuring uniform coverage and reduced waste.
Shaping the Future of Ice Cream
The success of Magnum Bon Bons highlights Unilever’s ability to innovate rapidly, addressing evolving consumer preferences while pioneering new manufacturing techniques.
“It’s been a fantastic team achievement, taking this project from concept to full industrialization,” said Paul Sherwood, Lead R&D Process Engineer.
With Bon Bons, Magnum sets a new benchmark for indulgence in a bite-sized format, paving the way for the next generation of ice cream innovations.
