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Automation in the Packaging Industry: Opportunities and Requirements
Sustainability targets, the European Packaging and Packaging Waste Regulation (PPWR), growing demand for post-consumer recycled (PCR) content, and the ongoing shortage of skilled labor are transforming the way packaging is designed and produced.
Production systems in the packaging industry are becoming faster, smarter, and more interconnected. However, technology alone does not create value. Packaging manufacturers need solutions that are easy to operate, easy to maintain, and flexible enough to scale with changing requirements.
Today, the real challenge is no longer introducing new technologies but successfully managing the increasing complexity of packaging processes.
Three key factors, in particular, will determine which companies can secure a long-term competitive advantage.
1. Ease of Use Despite Complex Technology
Modern packaging lines are achieving unprecedented levels of productivity. At the same time, companies are facing the challenge of compensating for labor shortages and limited technical expertise.
Operators are increasingly required to manage complex systems while continuously ensuring quality, efficiency, and process reliability.
The solution is not less automation, but smarter automation.
Technical complexity should remain in the background, while operation remains simple, transparent, and reliable for users. Successful solutions combine high performance with intuitive usability, easy maintenance, dependable support, and sustainable assistance throughout daily production operations.
2. The Rise of Data-Driven Manufacturing
At the same time, production data is becoming one of the most valuable resources in packaging manufacturing. As requirements for sustainability, traceability, and documentation continue to increase, transparency and effective data utilization are becoming increasingly important.
Key manufacturing and sustainability data include:
- Material composition
- PCR content
- Recyclability performance
- Production data
- Sustainability metrics
Many companies still rely on spreadsheets, PDFs, and disconnected systems. This limits transparency, slows decision-making, and reduces optimization potential.
When properly leveraged, however, data can become a strategic success factor for greater process stability, increased transparency, and improved operational control.
New Opportunities Through Digital Manufacturing
- Real-time process monitoring
- Material traceability
- Quality assurance
- Predictive maintenance
- AI-driven process optimization
- Sustainability reporting
3. Smart Services Create Value Beyond the Machine
Today, companies expect more than just a high-performance machine. They are looking for solutions that continuously contribute to high production performance throughout the entire lifecycle of their production systems.
Smart Services transform support from reactive troubleshooting into proactive performance management.
Components of Smart Service Solutions
- Remote Diagnostics: Rapid issue identification and shorter response times
- Predictive Maintenance: Early detection of potential failures before unplanned downtime occurs
- Digital Process Support: Continuous process optimization based on production data
- Expert Collaboration: Direct access to application and process specialists
The result is higher equipment availability, improved OEE (Overall Equipment Effectiveness), reduced scrap rates, and greater operational confidence.
Conclusion: Collaboration Is the Real Competitive Advantage
No company can achieve the goals of a circular economy alone.
Sustainable innovation requires collaboration among brand owners, retailers, converters, material suppliers, machine manufacturers, technology providers, and recycling companies.
When material selection, machine requirements, sustainability objectives, and production processes are aligned at an early stage, complexity can be reduced and innovation cycles accelerated.
As a result, the development of successful packaging solutions is increasingly based on connected value networks rather than isolated technologies.
How can automation be implemented intelligently and sustainably in the packaging industry?
This was the focus of our live discussion at interpack 2026. Our panel included:
- Dagmar Glatz (dm-drogerie markt GmbH + Co. KG)
- Thomas Reiner (Berndt & Partner)
- Olaf Clemens (SN Maschinenbau)
- Robert Hueber (Herrmann Ultraschall)
Access the recording here: