• Small businesses and start-ups that once relied on manual fulfillment are now investing in automated pack stations, void-fill machines, and robotic labeling.
• AI-driven filling systems ensure that only the exact amount of packaging material is used—which means no excess and no waste.
• Thanks to leasing and rental options, automation isn’t just for the big players anymore.

By Lindsey Naples

Introduction

There was a time when packaging was a purely manual process—all boxes were packed, sealed, and stacked by human hands alone. Today, with labor shortages, rising costs, and the constant push for efficiency, automation has stepped in to take the wheel (or the box). Although some may envision a robotics takeover of jobs within the industry, the reality is much less dramatic and much more necessary.

The influx of automation is causing the packaging industry to evolve very quickly, and automation’s market value is projected to hit a whopping $161 billion by 2033. That’s not just a trend—it’s a full-blown revolution. But why is automation becoming the go-to solution?

E-commerce Fuels the Automation Boom

In the past week alone, the odds are good that you’ve ordered something online…and you’re in very good company! Unfortunately, businesses are struggling to keep up with today’s instant gratification culture (did someone say next-day shipping?). Small businesses and start-ups that once relied on manual fulfillment are now investing in automated pack stations, void-fill machines, and robotic labeling. Even the so-called mom-and-pop shops are realizing that if they want to scale, they need to automate.

For example, a healthcare distributor that Keypoint Intelligence spoke with tackled skyrocketing labor costs, shipping expenses, and packaging waste by automating void-fill operations using artificial intelligence (AI)-driven scanners. The results included lower costs, less waste, and a more sustainable operation. That’s the kind of transformation that’s keeping automation in the spotlight.

Smarter Packaging and Sustainability

Sustainability is an outright necessity in today’s world. The packaging industry is facing mounting pressures to reduce waste, use recycled materials, and shrink its environmental footprint. In this regard, automation is proving to be a game-changer. AI-driven filling systems ensure that only the exact amount of packaging material is used—which means no excess and no waste. Businesses are also incorporating smart tracking with radio frequency identification (RFID) tags to manage reusable packaging (think crates, pallets, and containers that cycle back into use rather than ending up in landfills).

During the most recent Pack Expo event, sustainability and automation were major talking points. This is because businesses know that going green must be cost-effective to be viable, and automation is making it possible to strike that balance.

Some Roadblocks Remain

Despite its clear advantages, not everyone is jumping on the automation train. The primary roadblocks include cost and fear of the unknown, which are pretty practical reasons to be wary. Many businesses assume that automation is too expensive, but a collaborative robot can cost less than a family car. Additionally, thanks to leasing and rental options, automation isn’t just for the big players anymore—small businesses can also capture a spot on the playing field.

Some businesses worry that their employees won’t know how to operate or maintain automated systems, but the good news is that training is evolving too. Furthermore, younger generations who’ve grown up with technology will likely be more comfortable working alongside robotics systems. As digital natives continue to enter the workforce, the adoption of automation will only accelerate.

The Bottom Line

The packaging industry is at a crossroads. Businesses that embrace automation are helping to future-proof their operations, while those that resist may find themselves struggling to keep up in the future. This isn’t just about efficiency or cost savings; it’s about creating a safer, smarter, more sustainable industry by letting robots handle monotonous and/or dangerous tasks so human workers can focus on more important things.

The shift toward automation is happening whether we’re ready or not. The question is, will you ride the automation wave or get swept under it?

Lindsey Naples is an Editing and Proofreading Specialist at Keypoint Intelligence. In this role, she is responsible for copyediting and formatting a variety of content, from blogs to white papers and everything in between, while also writing the occasional blog herself. She graduated with a BA Degree in Literature from Ramapo College of New Jersey in 2014.