Stage 1
Education & Training
Operators train on production-grade twins
Universities, technical programs, and factory teams train on the same digital twins deployed in food extrusion lines.
Output:Trained operators
AI infrastructure · Starting with extrusion
The AI-native infrastructure layer for future food systems.
Meallions connects education, production, and equipment into one intelligent operating layer — helping food systems simulate, manufacture, verify, and scale nutritious products with precision.
Hardware+Software+Education+AI
- Real-time extrusion control
- Recipe & nutrient optimization
- Certified, traceable batches
Built with manufacturers, universities & equipment OEMs
Meallions / Equipment / DG75-II Twin-Screw ExtruderLive
Shift Afternoon 14:00–22:00 ActiveCrew 1 · lead TESTActive batches 1Open alarms 2Ingestor 5 Hz · 0 drops
DG75-II Twin-Screw Extruder
ReadyExtruder · Jinan DG Machinery Co. · DG75-II
Plant-1 · Singapore
extruder-int-001
Configuration
Type
Extruder
Integration
Enabled
Temp zones
6
Hoppers
5
Protocols
OPC_UAMODBUS
Max throughput
120 kg/h
Created
Apr 6, 2026
Updated
Apr 24, 2026
Identity
Vendor
Jinan DG Machinery Co.
Model
DG75-II
Factory
Plant-1
Location
Singapore
Nameplate
Screw Ø
75 mm
Max screw RPM
600
Max motor
55 kW
Mission & Vision
Hidden hunger is a manufacturing infrastructure problem.
The problem
“Solving hidden hunger at scale needs production systems that can adapt, control, verify, and prove every batch.”
Meallions is an AI-native digital twin platform for food extrusion manufacturing. We serve three segments — food manufacturers, universities, and equipment OEMs — with a mission rooted in eliminating micronutrient deficiency through better production tooling.
Nearly two billion people get enough calories but not enough essential nutrients. Solving that at scale requires production systems that can adapt recipes, control extrusion, verify nutrient quality, and prove every batch. Meallions mirrors food extrusion manufacturing in software — connecting ingredients, recipes, extrusion lines, QA, certificates, and traceability into one AI infrastructure layer.
AI infrastructure for food extrusion manufacturing — starting with extrusion.
Who We Serve
Built for manufacturers and OEMs.
Manufacturers and OEMs are the primary commercial audiences for Meallions. Operator training keeps the same digital twins on the workforce side, so every connected line strengthens the network.
For Education & Training
Train operators on the same digital twins factories deploy.
Factories deploy faster when operators understand the process before touching the line. Meallions gives universities, technical programs, and factory teams a simulation-based environment to train on real food extrusion workflows.
The same digital twins used in production drive operator training, QA practice, and traceability drills — building a workforce pipeline for food manufacturers.
- Simulation-based operator training
- Production-like food extrusion scenarios
- QA and traceability practice
- Faster onboarding for new plants
- Workforce pipeline for food manufacturers
Primary use case
For Manufacturers
Optimize food extrusion from recipe to certified batch.
Meallions helps manufacturers replace spreadsheets, reactive QA, and disconnected production data with a connected workflow for food extrusion manufacturing.
The platform mirrors each extrusion line, optimizes recipes against nutrition and cost targets, monitors runtime telemetry, and connects verified QA results to traceable batch records.
- Recipe optimization for nutrition, cost, and ingredient variability
- Digital twin simulation before production runs
- Runtime telemetry and extrusion stability monitoring
- QA verification tied to the batch record
- Certificates of Analysis and recall-ready traceability
- Pilot deployment on one extrusion line and one SKU
Onboarding · 4–6 weeks
Most extruders connect via OPC UA tag mapping. Send us your model and we'll scope a pilot.
For OEMs
Turn extrusion equipment into AI-ready production systems.
Meallions helps OEMs differentiate extrusion equipment with embedded telemetry, digital twin simulation, remote diagnostics, and software-attached revenue.
Equipment can arrive ready for smarter commissioning, operator training, predictive maintenance, and customer-specific production scenarios.
- Embedded telemetry and digital twin integration
- OPC UA / Modbus / PLC connectivity
- Remote diagnostics and predictive maintenance
- Co-branded simulation demos
- Performance benchmarking across installed equipment
- Recurring software revenue on top of hardware sales
The Meallions intelligence flywheel
Every connected production line strengthens the intelligence layer.
Stage 2
Manufacturing
Plants connect manufacture lines
Telemetry, QA results, ingredient behavior, and batch outcomes from each connected line improve the intelligence layer.
Output:Fortified batches
Stage 3
OEM distribution
OEMs embed Meallions into equipment
Embedded telemetry and digital twin integration turn each new machine into a connected production system that strengthens the network.
Output:Twin data streams
Current Partners
Trusted across food manufacturing, equipment, and workforce training
Meallions is co-developed with leading manufacturers, OEMs, and institutions shaping the future of food extrusion manufacturing.
University of Nairobi
Workforce training partner
Wilmar Business Indonesia
Food manufacturing partner
Jinan DG Machinery Co.
Equipment partner
The Meallions formula
Hardware + Software + Education + AI
Most food-tech companies pick one lane. Meallions integrates all four — the only way to actually move food extrusion manufacturing forward at scale.
Hardware+
Software+
Education+
AI
Hardware
Equipment we know inside-out
Co-developed with OEM partners like Jinan DG Machinery. Extruders, dryers, and coaters instrumented from day one — so software ships with the steel.
Software
A live digital twin per line
Recipe optimization, twin simulation, real-time process control, and traceable QA — one connected workflow replacing siloed spreadsheets.
Education
Trained operators & researchers
University partnerships turn the twin into a teaching environment. Operators, food scientists, and students learn on the same system that runs production.
AI
Models tuned for food extrusion
Nutrient retention, energy use, and yield predicted before the line starts. Every batch makes the next recipe smarter.
Rooted in our mission to eliminate micronutrient deficiency — by giving manufacturers, universities, and equipment OEMs a single intelligent system to build better food products, faster.
See the platform
Real screens from the operator console.
Light-theme panels straight from platform.meallions.com— status bar, equipment tabs, telemetry, and alarms.
platform.meallions.com
Equipment working process
Live mnemonic of the line — extruder, dosing and conveyors animated from real telemetry.
01 / 05
Platform
One operational intelligence layer for food extrusion manufacturing.
Four pillars connect ingredient intake, extrusion production, QA evidence, and operator training into one AI infrastructure layer.
Replace siloed spreadsheets, reactive QA, and disconnected production data with a connected workflow purpose-built for food extrusion.
Recipe Intelligence
Optimize fortified formulations across nutrition targets, ingredient costs, availability, and production constraints.
Digital Twin Operations
Simulate extrusion lines before production and monitor runtime conditions while the batch is running.
QA & Traceability
Connect inline readings, lab results, batch records, Certificates of Analysis, and recall evidence.
Industrial Learning Network
Use production-grade digital twins to improve operator training, OEM integration, and cross-site learning.
Workflow
From ingredient to certified batch.
Plan, simulate, produce, verify, and certify food products in one connected workflow. Every step writes back to the same batch record, so planning, production, QA, and compliance stay aligned.
01
Ingredient Intelligence
See what's in your silos and what each ingredient costs today. Track ingredient variability and approved suppliers before planning a single batch.
02
Recipe Optimization
Set nutrition and cost targets. The platform proposes approved formulas built from your ingredients and premixes against current prices.
03
Twin Simulation
Test every recipe in the digital twin. Predict yield, energy, and nutrient retention — and catch problems before the line is started.
04
Live Production Control
Send the approved recipe to the extruder. Runtime telemetry monitors extrusion stability and corrects drift to keep every batch on spec.
05
QA Verification
Lab and inline sensors cross-check finished product against the recipe spec. Any deviation is flagged on the batch record before release.
06
Certified Batch Release
Each batch ships with a signed Certificate of Analysis — recall-ready and fully traceable from raw intake to finished pallet.
Swipe to explore each step
Linked to step 01 · Educate
Streaming · 30sLive ingredient market feed
- 248.4-1.8%
Maize, yellow #2
USD / t · CBOT
- 312.1+2.4%
Wheat, milling
USD / t · Euronext
- 1,840+0.6%
Soy protein conc.
USD / t · Spot
- 86.5-3.1%
Vitamin A premix
USD / kg · Contract
- 14.2+1.2%
Iron (NaFeEDTA)
USD / kg · Spot
Recipe planning, repriced in real time
Every tick from contract, spot and exchange feeds is matched against your current bill of materials. The planner re-solves the recipe, projects unit economics for the next batch, and flags any spec or margin breach before you commit raw intake.
- Baseline COGS
- $412/ t
- Projected
- $408.6-0.8%
- Margin
- 11.4%on spec
- Auto-substitute ingredients when a cheaper, on-spec alternative appears.
- Lock procurement windows from forward curves, not last week's invoice.
- Push the repriced recipe straight into the digital twin for simulation.
Linked to step 02 · Experiment
Candidate recipes against your targets
RecipeProtein · CostFit
Maize–Soy Fortified
14.2% · $412
96Wheat–Pulse Blend
13.8% · $398
92High-Protein Premium
18% · $471
88
Targets in, recipes out
Set the nutrition envelope, cost ceiling and required premixes. The platform searches your approved ingredient catalog and returns recipes that meet spec — ranked by fit, cost and ingredient availability.
- Targets
- 7
- Candidates
- 24
- On spec
- 11ready
- Constraints: protein, fat, fibre, premix dose, allergens.
- Reuse approved formulas or branch a new variant in one click.
- Send any candidate to Simulate without re-entering data.
Linked to step 03 · Simulate
Digital twin of the extrusion line
- Predicted yield
- 98.2%+1.4
- Energy / t
- 184 kWh
- Throughput
- 3.6 t/h
- Moisture exit
- 11.8%
Operating window · die pressure
32 bartarget 4148 bar
Predict the batch before you start it
The twin models your specific line — screw configuration, die geometry, moisture, throughput. It returns expected yield, nutrition retention and energy use, plus the operating window that keeps the batch on spec.
- Compare scenarios side-by-side: cost vs. nutrition vs. throughput.
- Catch off-spec risk hours before raw material is committed.
- Approved scenario becomes the setpoint package for the line.
Linked to step 04 · Produce
Real-time control of the running batch
Pre-die pressure
41.2 barin windowBarrel zone 3
138 °Cin windowScrew load
62%in windowPremix dose
0.84 kg/minauto-trimMoisture in
16.1%in window
The plan runs itself — you supervise
Approved setpoints are pushed to the line. The platform watches every sensor, corrects drift inside the operating window, and pauses the line if a deviation would push the batch off spec.
- Batch
- B-2419
- Yield
- 97.8%
- Spec drift
- 0.3σstable
- Auto-trim premix dosing to absorb raw material variability.
- Every event is timestamped and tied to the batch record.
- Operators see the same numbers as the planner — no handover gap.
Linked to step 05 · Verify
Inline + lab cross-check before release
- 14.1%pass
Protein
target 14.0 ±0.5%
- 5.9%pass
Fat
target 6.0 ±0.4%
- 842 IU/gpass
Vitamin A
target ≥ 800 IU/g
- 63 ppmpass
Iron (NaFeEDTA)
target ≥ 60 ppm
- 11.8%pass
Moisture
target ≤ 12%
- 1.2 µg/kgpass
Aflatoxin B1
target ≤ 5 µg/kg
Every batch proven against its own spec
NIR scans, inline sensors and lab assays are reconciled against the recipe spec. Nothing leaves the warehouse until each parameter is inside its tolerance — and any deviation creates an investigation task automatically.
- Checks
- 34
- Pass rate
- 100%B-2419
- Lab time
- 42 min
- Inline NIR results reconciled with wet-lab assays automatically.
- Out-of-tolerance reading opens an investigation, blocks release.
- Verified results feed the certificate without re-keying.
Linked to step 06 · Certify
Signed certificate of analysis
Certificate of Analysis
CoA-2026-04-B2419
- Product
- Maize–Soy Fortified, 25 kg
- Batch
- B-2419
- Recipe rev.
- v3.4
- Released
- 2026-04-28 14:02 UTC
- Signed by
- QA Lead · cryptographic seal
All parameters within spec — released to warehouse.
One click, one signed document, full traceability
The certificate is generated from the verified batch record — recipe version, raw lots, line setpoints, lab results and operator signatures. Signed cryptographically, retrievable by QR or batch ID for audits and recalls.
- Recall window
- < 60s
- Standards
- ISO 22000
- Retention
- 7 yrimmutable
- One QR per pallet links to the full batch record.
- Aligned with ISO 22000, HACCP and customer audit packs.
- Recall any batch by ingredient lot in under a minute.
Implementation roadmap
A tailored rollout for every partner.
Pick your track — every phase has a measurable outcome and a clear next step.
For Manufacturers
90-day extrusion optimization pilot.
Prove Meallions on one extrusion line, one SKU, and one measurable production workflow before scaling across products, plants, and OEM networks.
Get a roadmap tailored to your manufacturers use case.
- 01Phase 01Week 1–2
Plant audit & baseline
Map the extrusion line, PLC signals, recipes, QA workflow, batch records, and current production baseline.
- Equipment & signal inventory
- Recipe and QA workflow baseline
- Production baseline report
- 02Phase 02Week 3–5
Twin setup & telemetry ingestion
Configure the digital twin, connect production data, ingest historical batches, and calibrate operating windows.
- Live telemetry connected
- Historical batch replay validated
- Operating windows calibrated
- 03Phase 03Week 6–8
Pilot line go-live
Run one SKU through recipe optimization, production monitoring, QA verification, and certificate generation.
- Fortified SKU producing on-spec
- Operator & QA training complete
- Certificates of Analysis generated
- 04Phase 04Week 9–12
ROI assessment & scale roadmap
Compare baseline vs optimized workflow. Assess waste, yield, QA time, and recall readiness, then define the scale-up plan.
- Baseline vs optimized production report
- Traceability readiness report
- Scale-up roadmap
FAQ
Answers for manufacturers, OEMs, and investors.
Practical questions we hear from production leaders, equipment partners, and investors evaluating Meallions as the intelligence layer for food extrusion manufacturing.
90-day food extrusion pilot
Start with one line. Scale into an intelligent production network.
Use Meallions to validate recipe optimization, extrusion stability, QA traceability, and operational ROI on one extrusion line before scaling across products, plants, and OEM networks.