Industrial Physics expert urges metal packaging industry to invest in automation

The metal packaging industry is now focusing on overcoming challenges through investment, process improvement, and greater adoption of modern measurement technologies, according to Stefan Welker, strategic segment manager for Rigid Packaging at Industrial Physics.

Recently, Industrial Physics published a report, titled Ready but not prepared: Metal packaging 2028 reality check, unveiling the mounting quality and production pressures in the sector.

Packaging Insights speaks to Welker about how manufacturers are balancing sustainability goals while maintaining the strength and performance of metal packaging.

What are the most important findings from your latest report?

Welker: The most glaring finding is that the metal packaging industry understands the challenges ahead but has not yet fully embraced the solutions already available. This is something that our team has experienced when analyzing the sector and working with customers, but the research helps to quantify the scale of this and spotlight where improvement can be made.

The research also highlights a quality detection challenge. Respondents identified quality issues being discovered too late in production as the leading technical risk facing metal beverage cans. In high-speed manufacturing environments, even a short delay in identifying a problem can result in substantial waste and rework.

Your report highlights structural integrity, cost control, and sustainability as top priorities. In what ways can the industry tackle these interconnected challenges?

Welker: What makes these priorities so interesting is that they are not independent of one another. In many ways, they are different expressions of the same underlying challenge. The industry is under increasing pressure to reduce material use, increase recycled content, and improve sustainability performance. At the same time, manufacturers must maintain the structural integrity of cans and ends while managing significant cost pressures linked to raw material volatility.

This creates a difficult situation for manufacturers to balance. Increasing recycled aluminum content supports circularity goals but can affect mechanical properties and pressure performance. Likewise, lightweighting reduces material use and cost but narrows performance margins.

To successfully navigate these challenges, manufacturers require greater visibility into how materials and processes interact. That means more precise measurement, stronger process control, and a deeper understanding of how changes in composition influence actual performance.

What strategies could be adopted to close the quality detection gap cited in your report and reduce operator dependency?

Welker: The challenge with late-stage detection is that the cost of a quality issue increases dramatically the longer it remains unnoticed. On today’s can-making and filling lines, large volumes can be produced before a problem is identified, leading to waste, rework, and lost productivity.

The first step in addressing this is increasing visibility. Manufacturers need more frequent measurement and faster access to quality data. Historically, quality control has often relied on periodic manual checks, which remain important, but may not always provide sufficient visibility into rapidly changing production environments.

Connected measurement systems, automated data collection, and stronger statistical process control can help address this challenge. These approaches allow manufacturers to identify trends and process drift earlier, before they result in production that does not meet specifications. 

Automation enables manufacturers to remove sources of inconsistency, increase measurement frequency, and generate more reliable data.Manual processes introduce variability, particularly when measurements must be repeated across multiple shifts or facilities. Automation improves repeatability and consistency while allowing skilled personnel to focus on analysis and process improvement.

The objective is to create a quality system that provides earlier insight, greater confidence, and a more proactive approach to process control.

How do regional variations influence operations, investment, and technology deployment across different markets?

Welker: The regional differences revealed by our research reflect the fact that manufacturers operate within different economic, regulatory, and supply chain environments.

India demonstrated the highest confidence in supply chain resilience, which likely reflects strong domestic aluminum production, robust supply infrastructure, and continued market growth. Germany also reported high confidence despite ongoing industrial challenges, reflecting the strength of its manufacturing ecosystem and established supplier networks.

The UK and US presented a more cautious picture. In the UK, post-Brexit supply chain complexities continue to create uncertainty, while manufacturers remain indirectly affected by European regulatory developments. In the US, trade policy volatility and tariff-related concerns are influencing how companies think about raw material availability and long-term planning.

These differences influence investment decisions because confidence often affects willingness to commit to new technologies and operational change. However, one theme was consistent across all markets: manufacturers recognize that sustainability requirements, production complexity, and quality expectations are increasing.

How do you see the EU metal packaging industry evolving in the next few years?

Welker: Over the next few years, I expect the European metal packaging sector to become increasingly focused on balancing sustainability ambitions with manufacturing realities.

Regulatory pressures will continue to drive demand for higher recycled content and improved circularity. At the same time, manufacturers must maintain structural performance, production efficiency, and product quality. This is likely to accelerate investment in material science, process optimization, and advanced quality systems.

We are also likely to see greater adoption of automation and connected manufacturing technologies. As production complexity increases, manufacturers will need more integrated approaches to quality control, traceability, and data management.

Another important trend will be flexibility. Brand owners are demanding greater product differentiation, shorter production runs, and more frequent changeovers. Supporting this level of agility requires testing and measurement systems that can adapt quickly without compromising accuracy or efficiency.

The industry’s success will depend less on whether it understands the challenges ahead and more on how quickly it acts. The technology exists to support the transition. The organizations that invest now in measurement, automation, and process visibility will be best positioned to meet regulatory requirements and commercial expectations as 2030 approaches.