Packaging machinery in 2023: Automation, AI, labor shortages and palletizing lead industry advancements

20 Dec 2023 --- With the swift proliferation of automated machinery amid the COVID-19 lockdowns, the market has seen sustained growth in adaptation and acceleration this year. Packaging Insights’ industry review finds that packaging businesses are progressively turning to technologies such as AI, robotic systems and advanced machinery to enhance efficiency in work processes and safeguard against potential labor shortages.

While automation significantly benefits the industry, it presents numerous challenges, particularly with investment costs and skilled labor requirements. We spoke to industry leaders at Berhalter, Syntegon and Cama Group to discuss the latest developments and challenges automation brings to the packaging industry. 

At Interpack 2023 in Düsseldorf, Germany, in May, packagers displayed automation and digitalization as key topics across all trade show halls. Upheavals caused by the COVID-19 pandemic led to industry innovations for remote access and virtual reality solutions, while e-commerce became indispensable. At the event, we spoke to Balluff, Sidel, Schubert, IMA Group, Tna Solutions and Sea Vision Group about the companies’ novel machines presented on the show floor.

Furthermore, IMA Group addressed the packaging challenges of the food and dairy industry at Pack Expo 2023 in Las Vegas, US. Ahead of the trade show in September, we talked to Dan Margherio, business development manager for IMA Dairy & Food US, who told us that the industry continues to witness a “hyper-competitiveness” for labor, partly driven by the ripple effects of the post-COVID-19 “Great Resignation.”

PET Technologies’ APF-Max 2 blow molding machine.“Encouragingly, maintenance-free high-speed filling lines are helping to alleviate labor and staff shortages. Specialization is another tool, with many multinational trade partners combating the increasing dearth of technical experience with specific and recurring training programs directly supported by suppliers and manufacturers,” said Margherio.

PET innovations
Earlier this year, Sidel introduced the EvoBlow XL machine, reportedly “the largest blower” for PET bottles of sizes up to 10 L. The machine is suitable for water, edible oil and food markets. 

“As the demand for rPET continues to rise, EvoBlow XL has been developed to manage the challenges associated with rPET grades and possesses proven process capabilities from virgin PET to up to 100% rPET,” the company shared.

At the recent BrauBeviale trade show in Nuremberg, Germany, F&B machinery innovation was a leading trend. At the event, which took place last month, companies showcased their latest filling, blow molding and processing machinery developments. 

PET Technologies presented its APF-Max 2 blow molding machine. The Ukraine-based blow molding machines manufacturer produces automatic machines for PET bottles. The company also makes blow molds, together with design corrections for PET bottles for its equipment and other existing low molding machines.

Palletizing and stretch wrapping
The pallet and palletizing industries are also undergoing continuous development to reduce the environmental footprint of packaging supply chains. We discussed the latest industry trends with Fanuc Europe and Tosca, exploring innovations for special palletizing robots and sustainable pallets.

At Pack Expo 2023, Beumer Group showcased its Beumer stretch hood packaging system. The system is manufactured in a modular design and covers palletized or disorderly palletized goods with its stretch hood film. Box palletizing with the M-410 series (Image credit: Fanuc).

Marvin Krampe, segment manager of Products at Beumer, told Packaging Insights that the packaging system allows the goods to be safely protected from environmental influences such as sun, dirt and moisture during handling and outdoor storage.

Also at Pack Expo, Cama Group exhibited its IT series loading system with a 2-axis integrated robot. As a part of Cama’s BreakThrough Generation Series, the system features a Monoblock frame with a hygienic and ergonomic design. Key benefits of this machine include its flexibility, safe and easily accessible stainless-steel frame. 

“Our top loading systems can pack various products, including flow-wrapped packages such as snack bars, confectionery, cartons, pouches and bags,” Billy Goodman, managing director at Cama North America, told us.

Furthermore, Mondi partnered with Robopac, a manufacturer of pallet-wrapping machinery, to offer a paper-wrapping solution for pallet storage and transportation called the Advantage StretchWrap. Robopac’s semi-automated and fully automated machines can take Mondi’s Advantage StretchWrap, allowing customers to replace “unnecessary” plastic, which remains to be the industry standard for pallet wrapping.

Meanwhile, Bizerba and Fabbri Group announced the development of solutions for the food packaging sector using a new range of combined and integrated packaging machines that will be offered in combination with packaging materials. The partnership also provided technical support and spare parts services from a single source.

Andreas W. Kraut, CEO and shareholder of Bizerba, told us that the hybrid stretch wrapper based on the use of recyclable monomaterial films produced by Fabbri Group makes packaging “more sustainable.” Bizerba complements the packaging machine based on Stretch Film Wrapping technology with solutions for slicing, weighing, labeling and checkout tasks.

Paper production machines 
In September, PulPac unveiled the “world’s first injection molding machine for fiber-based products” dubbed PulPac Scala. The machine platform combines injection molding with PulPac’s Mill-to-Web fiber unit to make Dry Molded Fiber technology more accessible and cost-effective.

PulPac unveiled the “world’s first” injection molding machine for fiber-based products (Image credit: PulPac).Viktor Börjesson, chief partnership officer at PulPac, spoke to Packaging Insights about the launch and stressed the urgency of finding fossil-fuel-free alternatives: “Plastic is a giant problem. The need for fossil-fuel-free alternatives is urgent, and fiber has the upper hand when replacing single-use plastics.”

Meanwhile, Microline developed a specific feeding system for interfolded products to remain soft in the tissue industry and secondary packaging. The system can keep the product properly oriented while ensuring gentle handling without reducing production performance. Interfolded products from the tissue sector come with specific dynamics that bring particular technological challenges to the various supply chain stakeholders. The system can be used for products like wipes, paper towels and hospital paper rolls.

Finally, Greece-based DS Smith Hellas invested €33.9 million (US$37.5 million) to purchase new machinery for innovative packaging solutions and capacity enhancements. The investment plan will be implemented over the next two years across the packaging giant’s three sites in the country. 

The move supports plastic replacement, increases capacity and boosts productivity. The business aims to differentiate itself in the market by supporting customers in reaching their environmental targets.

By Natalie Schwertheim