Why packaging is going automated

The packaging industry is undergoing a seismic shift, driven by cutting-edge automation technologies that streamline operations and improve sustainability. Credit: wellphoto / Shutterstock

I​​​​​​​n recent years, the packaging industry has witnessed a transformative shift with the integration of advanced automation technologies. From robotic assembly lines to AI-powered quality control systems, these innovations are enhancing efficiency, reducing costs, and addressing labour shortages. 

 Moreover, automation is playing a pivotal role in promoting sustainability by minimising waste and optimising material usage. 

Secondary packaging, which involves grouping primary packaged products for distribution, has seen significant advancements through robotics. Modern robots are adept at tasks such as feeding cartons, pick-and-place case packing, and various palletising configurations, all requiring high precision and speed.  

A report by PMMI Business Intelligence indicates that robots and collaborative robots (cobots) are expected to be present in 95% of all secondary packaging lines within the next decade. 

 This surge is driven by the need for flexibility, especially with the proliferation of product variations and the demand for faster production runs. Additionally, 85% of companies are looking to expand their automation solutions in secondary packaging to achieve quicker changeovers and meet production goals.  

Quality control is paramount in packaging, and AI-powered inspection systems are at the forefront of ensuring product integrity. These systems utilise advanced cameras and machine learning algorithms to detect defects, ensuring that only products meeting stringent standards proceed to market.  

For instance, AI-enhanced cameras are being used to manage stock and customer interactions, while AI tools assist with inventory forecasting and personalised marketing.

Digital twin simulations further complement these advancements by creating virtual replicas of physical systems. Companies like Krones have developed digital twins of their package-handling robots, enabling them to optimise designs, conduct fault testing, and support predictive maintenance.

By simulating real-world operations, businesses can identify potential issues before they arise, reducing downtime and enhancing overall system performance.

Automation is not only about efficiency but also sustainability. By implementing automated systems, companies can significantly reduce material waste and energy consumption.  

For example, Treasury Wine Estates invested $10 million in creating a fully autonomous barrel hall featuring driverless forklifts and robots for data collection and barrel movement.  

This system increased production capacity by 60% and aligned with the company's net-zero goals by 2030 through the use of electric autonomous vehicles.  

Furthermore, AI tools help retailers optimise operations and reduce waste. For instance, Sainsbury's, Tesco, and Waitrose are leveraging AI to improve inventory management, thereby minimising waste and enhancing sustainability.  

Ultimately, the integration of automation technologies in packaging is ushering in a new era of efficiency, cost-effectiveness, and sustainability.  

As these technologies continue to evolve, businesses that embrace them will be well-positioned to meet the demands of the modern market while contributing to a more sustainable future.