Inside Mars' Bold Global Manufacturing Strategy
Mars is a global, family-owned company renowned for its diverse portfolio, spanning confectionery, pet care and food products.
As of 2025, Mars continues to be a major player in the industry, with annual revenues exceeding US$50bn and a workforce of approximately 140,000 worldwide.
The company’s manufacturing strategy revolves around sustainability, innovation and supply chain resilience, ensuring long-term growth and efficiency.
Mars' approach to manufacturing in 2025 is driven by three core pillars: sustainability, digital transformation and supply chain resilience.
These initiatives are integral to maintaining operational excellence and meeting the evolving demands of global consumers.
Sustainability Initiatives
Mars has set an ambitious goal of achieving net-zero greenhouse gas emissions across its entire value chain by 2050.
To achieve this, the company is implementing several key measures:
Renewable energy investments: Mars is expanding its use of wind and solar power to reduce reliance on fossil fuels across its factories. For example, its UK operations are powered entirely by a wind farm in Scotland, while solar farms supply energy to facilities in the US and Australia.
Sustainable sourcing: Mars is prioritising responsibly sourced raw materials to minimise environmental impact. This includes using 100% RSPO-certified sustainable palm oil and working towards fully traceable cocoa sourcing through its Cocoa for Generations programme, which supports farmers with improved agricultural practices and income diversification.
Waste Reduction: Mars seeks to reduce food waste and optimising packaging materials. It has committed to making all packaging recyclable, reusable or compostable by 2025 and is investing in alternatives such as paper-based wrappers for its confectionery products. Additionally, the company is working to halve food waste within its own operations and across its supply chain.
By embedding sustainability into its operations, Mars is not only aligning itself with global environmental goals but also ensuring long-term business resilience in a changing climate.
"Our plan to be Sustainable in a Generation, our Five Principles and our culture of ethics will help create a better world for all of us," says Stefanie Straub, Vice President, General Counsel & Corporate Secretary.
Digital transformation
In 2025, Mars continues to leverage cutting-edge technologies to enhance its manufacturing processes and drive efficiency.
Key aspects of its digital transformation strategy include:
AI: Mars uses AI-driven predictive maintenance and quality control systems help reduce downtime and enhance production efficiency. Within its factories machine learning algorithms analyse equipment performance to detect potential failures before they occur, minimising disruptions. The manufacturer also utilises AI-powered vision systems to ensure product consistency by identifying defects in real time.
Cloud computing: Centralised data analytics improve decision-making across Mars' global operations. By integrating cloud platforms, the company can track supply chain performance, monitor energy usage and optimise production scheduling, leading to greater agility and cost savings.
Digital twin models: Digital twins of manufacturing environments enable real-time monitoring, testing and optimisation without real-world risks and costs. Mars is using digital twins to model factory layouts, test process improvements and predict the impact of changes before implementing them in physical plants, ensuring consistent product quality and operational efficiency.
These advancements enable Mars to stay ahead of industry trends, enhance sustainability efforts and respond swiftly to market demands.
Supply chain resilience
To mitigate risks and improve agility, Mars has strengthened its supply chain through:
End-to-end visibility: Advanced tracking and analytics provide real-time insights into supply chain performance. By leveraging IoT sensors and blockchain technology, Mars can monitor raw material sourcing, track shipments and detect potential bottlenecks, ensuring greater transparency and faster response times.
Advanced planning systems: Mars also uses AI-powered forecasting tools optimise production scheduling and inventory management. These systems analyse historical data, market trends and external factors such as weather patterns to predict demand more accurately, reducing waste and preventing stock shortages.
Diversified Sourcing Strategies: By reducing dependence on single-source suppliers, Mars minimises disruptions and ensures consistent product availability. The company works closely with multiple suppliers across different regions, securing alternative sources for key ingredients like cocoa and vanilla to safeguard against geopolitical or climate-related risks.
This strategic approach allows Mars to navigate global challenges while maintaining high levels of efficiency, resilience and reliability.
Expansion and acquisitions
Other factors shaping Mars' manufacturing strategy include the company's recent acquisitions and continual pursuit of growth and expansion.
Mars operates an extensive global network of manufacturing facilities to support its diverse product range and ensure efficient distribution.
The manufacturer operates 135 factories across 68 countries, with 22 alone based in the US.
In 2024 Mars acquired snacking leader Kellanova, a move which has shaped its manufacturing trajectory and product portfolio ever since.
“In welcoming Kellanova’s portfolio of growing global brands, we have a substantial opportunity for Mars to further develop a sustainable snacking business that is fit for the future," says Poul Weihrauch, CEO of Mars.
"We will honor the heritage and innovation behind Kellanova’s incredible snacking and food brands while combining our respective strengths to deliver more choice and innovation to consumers and customers.
"We have tremendous respect for the storied legacy that Kellanova has built and look forward to welcoming the Kellanova team.”
The acquisition has helped greatly boost Mars' manufacturing strategy in 2025, one built on sustainability, digital innovation and supply chain resilience.
With a vast global network of facilities and continuous investment in advanced manufacturing technologies, Mars is well-positioned to maintain its industry leadership.
By prioritising responsible sourcing, leveraging AI and automation, and strengthening its supply chain, Mars is ensuring long-term success while meeting the evolving needs of consumers worldwide.
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