The packaging industry is changing fast. Labor shortages, rising costs, and growing demand for efficiency are forcing manufacturers to rethink operations.
By 2030, the global manufacturing sector will face an 8-million-worker shortage, making automation a necessity. Meanwhile, the global packaging automation market is projected to hit $86.72 billion by 2025, signaling a major shift.
For manufacturers, the challenge isn’t whether to automate — it’s how to do it effectively. The right packaging automation solutions not only improve production speed and maintain product quality but also increase profitability across every cycle.
However, automation doesn’t automatically require a full production line overhaul. Companies are integrating automation more completely and successfully than in years past, but also more efficiently.
How?
The key is identifying and understanding vital areas where automation is most effective, asking the right questions pre-integration, and proactively overcoming challenges to gain advantages only production automation can offer.
IDENTIFY THE BEST AREAS TO AUTOMATE
Successful producers start by automating high-impact areas, even integrating “value-added automation” in key phases of the packaging process, to alleviate production challenges while remaining cost-effective:
Product Inspection
Bypassing manual vision inspection and opting to automate with advanced vision technology can reduce product defects by up to 25-30%, ensuring optimal packaging safety and accuracy and avoiding costly recalls.
Primary Packaging
Automated filling, wrapping, and sealing systems can boost output by up to 30% while lowering labor costs, alleviating reliance on manual processes, and ensuring optimal product quality.
Secondary Packaging
Case packing and tote management can reduce operating expenses by up to 20% or more and improve product per package/package per case accuracy, coding and labeling, and regulatory compliance.
Palletizing
Automating stacking and wrapping can replace up to 20 manual workers per shift, improving throughput by up to 50% and reskilling employees for improved job placement and satisfaction.
OVERCOMING BARRIERS TO AUTOMATION
Despite proven success, many manufacturers hesitate to automate production due to common, prevalent, perceived obstacles. Yet employing automation addresses many of these challenges simultaneously while delivering the speed, savings, and consistent quality the market demands:
- Cost: Targeted packaging automation delivers ROI in under two years (on avg.) — with some companies breaking even within 12 months or less.
- Labor Concerns: Automation allows employees to shift into higher-value roles, increasing employee retention by up to 30%.
- Space Limitations: Modern automation systems are 30% more compact than past models, making integration easier without costly expansion.
MEASURING THE IMPACT OF PACKAGING AUTOMATION
Most importantly, producers that automate production see measurable improvements across key metrics, year over year vs. manual operations:
- Productivity Gains: Automated systems increase output by up to 22% per year.
- Cost Savings: Automation has proved savings of up to $450 billion annually by automating key processes.
- Scalability: Automation enables expansion without significantly increasing labor costs.
- Quality Control: Vision inspection reduces human error, ensuring near-perfect product consistency.
CHOOSING THE RIGHT PACKAGING AUTOMATION PARTNER
Finally, success depends on more than just technology — it requires the right partner. A trusted OEM provides tailored automation solutions, seamless integration, and maximum efficiency, all attuned to your production and goals.
Choosing packaging experts who apply lean manufacturing principles improves flexibility, conserves resources, and reduces waste, while integrating technologies like collaborative robotics (COBOTS) to make automation more accessible. This helps you future-proof operations and drive long-term success.
THE TIME TO AUTOMATE IS NOW
Labor shortages persist, and demand is rising. Automation is no longer optional — it’s essential for survival and success. The question isn’t whether you can afford to automate—it’s whether you can afford not to.
