Nestlé India has made a significant leap in its supply chain transformation by launching a Next generation distribution centre (DC) in Bhiwandi, Maharashtra. This state-of-the-art facility not only enhances operational efficiency but also brings sustainability and digital innovation to the forefront. The new hub incorporates cutting-edge digital twin technology while leveraging LNG-powered trucks to minimize environmental impact across key transportation routes.
With rising demands for sustainable practices and technological integration in logistics, Nestlé’s latest initiative demonstrates its commitment to building a future-ready supply chain. By prioritizing digital innovation and green mobility, the company aims to reduce emissions, streamline processes, and set a new benchmark in India’s FMCG sector.
Revolutionizing Supply Chains with Digital Twin Technology
Nestlé India has integrated digital twin technology into the Bhiwandi hub, enabling the creation of a real-time virtual model of operations. This digital model allows the company to simulate, monitor, and optimize logistics activities without affecting the actual physical processes.
With real-time data, Nestlé can track operations continuously, predict bottlenecks, and implement proactive solutions to reduce operational inefficiencies. As a result, the company ensures smoother workflows, reduced downtime, and more reliable service delivery for its products nationwide.
Moreover, by simulating different logistics scenarios, Nestlé gains actionable insights that drive faster and more informed decision-making across its supply chain. Therefore, the hub marks a shift towards data-driven logistics management with measurable efficiency and sustainability outcomes.
Boosting Efficiency with Larger Capacity
Featuring around 20,000 pallet positions and the largest cold room dedicated to chocolate storage within Nestlé India’s distribution network, the facility sets a new standard for logistics infrastructure in the country. Constructed in a record seven months, the distribution centre incorporates advanced technologies such as AI-powered CCTV surveillance, a digital rack inspection system, a centralised Operations Command Hub, and sensor-equipped material handling equipment to enhance both security and efficiency.
Significantly, the Bhiwandi facility also houses India’s first shuttle racking system—an advanced high-density storage solution aimed at maximising space efficiency. It also features a dedicated repacking unit and operates on fully digital systems, completely eliminating paper-based workflows.
“Efficiency, agility, safety, and sustainability are integral to our value chain,” said Varun Gupta, Head of Supply Chain at Nestlé India. “The Bhiwandi Distribution Centre exemplifies our team’s innovation and incredible efforts bringing together optimal automation, synchronised planning using Al and machine learning, and unique omnichannel service offerings for our customers.”
Reflecting Nestlé’s global Net Zero ambition, the company has begun transitioning toward more sustainable logistics. Today, around 25% of cargo along the Sanand–Bhiwandi route is transported via alternative fuel vehicles, significantly cutting greenhouse gas emissions. Supporting this sustainability drive, Nestlé India has also launched an Operations Command Hub and a Logistics Operations Competence Centre as part of its broader logistics transformation efforts.
This milestone at Bhiwandi was made possible through Nestlé’s ongoing collaboration with logistics partners, with plans underway to expand the adoption of alternative fuel transportation across major freight corridors.
As global supply chains navigate the demands of digitalization and environmental responsibility, Nestlé India’s Bhiwandi hub emerges as a forward-thinking model—one that champions Digital Twin planning and green logistics as pillars of operational excellence.
