In past years, we have seen the arrival of ever-new catchphrases for the description of digitalisation: Big Data, Cloud, Artificial Intelligence or smart sensors are terms often used in this context.
To what extent do the technologies behind them define the processes in the sweets and snacks industry? ProSweets Cologne provides answers to this question and will show where AI-based automation and data-driven quality assurance make a difference from the 1st to the 4th of February 2026.
The manufacturers of sweets and snacks are facing a variety of challenges. New packaging lines must be quickly ready to operate so that production schedules can be maintained.
At the same time, the output quantities must be achieved stably, and overall system effectiveness must be permanently assured, without malfunctions or downtimes. This is complemented by the need to adapt at all times to market requirements and consumer preferences, as variety at the point of sale is increasing – and not only for the products themselves.
From the family pack with a mixed assortment to the practical snack package for on the go, and exclusive limited editions, consumers expect a wide range of variants and options for personalisation.
Mechanical engineering meets Big Data in Cologne
The consequence is that systems must be retooled more often. Efficiency, high machine availability, and ease of operation are at the forefront of system development.
"Called for are highly flexible solutions that allow easy and quick format changes and are subsequently quickly ready to use again. Those who modernise and have no fear of new technologies remain competitive", said Guido Hentschke, Director of ISM Ingredients and ProSweets Cologne.
With their numerous sensors and actuators, the systems in the sweets and snacks industry have long been highly automated, but not consistently data-supported. The producing companies require solutions that prepare enormous quantities of, in some cases, unused data for process optimisations. These can be found on the Cologne fairgrounds.
As a first step toward digital transformation, technology providers are integrating intelligent sensors into existing systems and configuring them to communicate with the Cloud. "Smart" sensors, equipped with an integrated microprocessor, not only record physical measured values but also perform signal preparation tasks. They, in this way, enable reliable forecasts of the operating conditions of the systems, which in turn offer further possibilities for improving overall equipment effectiveness (OEE).
Generative copilots for operation
In addition to continuous monitoring, the manufacturers of sweets and snacks can query their production and packaging systems via AI-supported assistants. The generative chatbots, which interact with a knowledge database, provide immediate answers to all operational questions.
The basis of data, constantly growing through machine learning, can provide assistance in communication with the machines and contribute to the optimisation of production efficiency. The assistants can help automate routine tasks. In combination with guided format changes, companies establish efficient processes in this way, where every step is verified. Production interruptions due to false-format parts can be eliminated.
The sensors don't always have to be installed statically and directly in the systems. Common polycarbonate moulds that pass through a chocolate system equipped with measurement technology can examine areas that are difficult to see, such as refrigerators, shaping stations, and areas with vibration.
Mechanical influence parameters and temperatures can thus be monitored in real time. The sensors recognise, for example, transitions with non-parallel chains in a casting system, in that the mould revolves around the vertical axis. Errors can be detected early on in this way, making it possible to initiate targeted measures before malfunctions occur.
Sensors with integrated intelligence
Smart sensors provide a perfect foundation for implementing Artificial Intelligence to make data-driven decisions.
"AI and machine learning are high-performance technologies with the potential to enduringly change the manufacture of sweets and snacks. Even today, the systems act increasingly proactively, with the goal of improving quality standards and deploying resources more efficiently", Guido Hentschke emphasised.
Against this background, image-processing 2D and 3D vision sensors are currently on the march throughout the food industry. They guarantee that other products, in different formats or with new packaging tasks, can be processed without additional effort on the same system.
The right product handling also makes a difference. Using AI-based image recognition, robots recognise different objects and reliably master the "grasp into disorder".
Behind this is sophisticated vision technology combined with five or six-axis pick-and-place kinematics. Evenly arranged in the tray or flow bag, the cookies or crackers already convince with their quality and optimal presentation when the package is opened. The bandwidth of possible deployment areas for systems of this kind knows no bounds.
Trade visitors to ProSweets Cologne can experience the advantages of new systems firsthand during live demonstrations at the stands.
Recognising foreign bodies in real time
In addition to high-performance pick-and-place applications, AI-supported vision sensors are, in the meantime, also a fixed element of quality assurance. They can classify gummy bears, bonbons or chocolates according to defined criteria as well as check portions and packages for the correct content and quantity.
Progressive systems thereby rely on multispectral imaging. They recognise the chemical composition of foreign bodies in real time and identify glass and metal fragments or plastic particles in food products and packaging where this has to date not been possible. They can also sort out defective products, such as crumbled cookies or waffles with incorrect chocolate coatings – and that with a precision surpassing even the most experienced quality tester.
Deep learning-supported algorithms not only make a decisive contribution to increasing line efficiency. They can also be deployed in the context of automatic classification of raw materials, for example, for determining the quality of cacao beans.
Through the provision of image material, the software can recognise defects like insect infestation or mould and determine the degree of fermentation using a colour schematic. This makes it possible to undertake targeted measures for preserving the characteristic chocolate flavour.
Responses to the challenges of tomorrow
Visitors can discover the current role of AI in optimising production processes and its implications for the future at ProSweets Cologne. The international trade fair for suppliers to the sweets and snacks industry, which takes place in parallel with ISM and ISM Ingredients in Cologne, also aims to address two further challenges facing the industry: the acute shortage of skilled workers and increasing cost pressures.
Furthermore, the accompanying event programme addresses the major future themes of the industry and provides practical insights and guidance for manufacturers and suppliers. The focus here is on:
- Technological innovations: how sustainable and AI-supported solutions can make processes more efficient and future-proof.
- Innovative ingredients and processing technologies: new approaches that help sweets manufacturers make products healthier, more attractive and more marketable.
- Global crises as a challenge: from supply chain resilience to geopolitical uncertainties – strategies for allowing companies to remain resilient.
- Sustainable packaging: materials and concepts that combine environmental friendliness with functionality.
- Retail experience: how packaging at the POS becomes a brand experience and influences purchasing decisions.
- Focus on shelf marketing: why packaging builds a bridge between brand, marketing and people, today more than ever.
In this way, ProSweets Cologne 2026 positions itself not only as an international industry platform but also as a provider of impulses for answers to the most urgent questions of tomorrow.
