Unilever’s latest creation, Magnum Bon Bon, has hit the market, offering premium, bite-sized indulgence in 12-piece shareable tubs. Designed for modern consumers, especially Gen Z, these treats combine Magnum’s signature creamy ice cream with a cracking chocolate shell and indulgent sauce ribbons—all in a smaller, more convenient format.
With Gen Z’s penchant for snacks and portion-controlled treats, Magnum Bon Bons cater to a growing demand for indulgent, sharable products. Research shows 90% of Gen Z snacks daily, with a preference for unique flavors and textures.
Challenges in Miniaturization
Creating bite-sized versions of Magnum’s iconic ice cream posed significant challenges. Unlike full-sized bars, Bon Bons are finger-friendly and require precise engineering to replicate Magnum’s signature taste and texture. Key obstacles included:
- Ensuring a slow-melting formulation for better handling.
- Achieving consistent chocolate coating with embedded sauce ribbons.
- Developing a robust packing process for cold chain logistics.
Advanced R&D: The Backbone of Bon Bon Production
Magnum Bon Bon’s development was driven by Unilever’s Advanced Prototype Engineering Centre and Advanced Manufacturing Centre in the UK. These state-of-the-art facilities leveraged cutting-edge technology to accelerate innovation.
- 3D Printing & CAD/CAM: Engineers designed and tested prototypes to determine the optimal Bon Bon size for packing and transportation.
- Pilot-Scale Testing: Small batch runs tested efficiency, reduced waste, and optimized production.
- Chocolate Enrobing Process: A custom-designed “chocolate waterfall” covers thousands of ice cream bites per minute with minimal waste, ensuring a consistent product.
Unilever’s process line for Magnum Bon Bons can produce over 200 million pieces annually. Sophisticated systems ensure precise dosing of ice cream, chocolate, and inclusions, maintaining the product’s quality and taste across large volumes.
Magnum Bon Bon’s launch showcases Unilever’s ability to combine robotics, AI, and advanced manufacturing to bring innovative products to market quickly. The success of this project underscores the company’s future-ready capabilities in ice cream production and its responsiveness to evolving consumer preferences.
“It has been a fantastic team achievement to take this project from idea through to full industrialization,” said Paul Sherwood, Lead R&D Process Engineer.
Magnum Bon Bons are now available in stores, offering a premium, bite-sized indulgence perfect for today’s snack-savvy consumers.