The transformative potential of artificial intelligence (AI) in packaging could bring about the next great era of integrated UK industry operations, according to Think B2B Marketing Managing Director Joanna Stephenson, following her keynote talk on the subject at the recent Esko Label & Packaging Forum.

"We say it a lot, but it really is an exciting time for the global packaging industry and as we look to 2025, this could be the year we make that next major step-change. For years, we've talked about Industry 4.0 in packaging and printing as though it were a distant ambition, but AI is rapidly emerging as the force that could make truly connected smart manufacturing a reality," says Joanna.

"There's a lingering misconception – and the packaging industry isn’t alone in this - that AI-driven technologies are exclusively for major players with deep pockets and in-house tech teams. We saw the same hesitancy when automation first emerged, but that's simply not the case anymore. How many packaging businesses, from SMEs to multinational players, now rely on automation from prepress through to production? The barrier to entry for AI implementation is lower than many realise, and the potential benefits for SMEs and independent converters are substantial.

“As I detailed at the Esko Label & Packaging Forum we're seeing the emergence of accessible AI solutions that can transform every aspect of packaging production, from enhanced quality control through machine vision systems to predictive maintenance that prevents costly downtime to shore up costs in a most price-sensitive market. These aren't just efficiency improvements – they're fundamental changes in how we approach manufacturing challenges. It’s the kind of technological shift that comes along maybe once or twice in a generation.

“Perhaps most excitingly, and certainly for our team as a packaging communications and marketing specialist, AI is proving to be a powerful ally in our industry's sustainability journey. The technology's ability to crunch vast amounts of data and identify patterns is helping converters optimise material usage, reduce waste, and make more informed decisions about energy consumption. These are things that even the most experienced eye could miss. We're seeing AI being used to fine-tune production processes in ways that would be impossible for human operators alone, leading to significant reductions in waste and improved sustainability metrics – right when the packaging industry is under heightened scrutiny.

“The integration of AI with existing automation systems is also opening new possibilities for workflow optimisation. From many of our conversations with clients and partners, we’re seeing smart algorithms analysing production data in real-time, making split-second decisions about resource allocation and scheduling that maximise efficiency and lessen our reliance on natural resources. This level of integration and optimisation was simply unimaginable just a few years ago, so it’s no surprise that AI’s potential is so vast.

“What's particularly encouraging is how AI can help packaging businesses develop a more comprehensive view of their operations. It's not just about collecting data – it's about drawing meaningful insights that can drive real improvements in efficiency, sustainability, and profitability. For instance, AI can analyse patterns in customer orders, production schedules, and material usage to identify opportunities for optimisation that might be invisible to the human eye.

“Looking further ahead, I’m also expecting to see AI helping to optimise packaging designs themselves, not by creating artwork directly, but by providing designers with fresh insight into consumer behaviour and engagement. By analysing data on how customers interact with packaging in-store – where their eye is drawn first, what information they seek out, how they engage with different design elements – AI could help design teams create packaging that's scientifically optimised for maximum shelf appeal and usability. This fusion of creative design talent with AI-driven consumer insight could transform how we approach packaging aesthetics.

“The journey to Industry 4.0 in packaging has been marked by innovation at every step, but AI could be the catalyst that finally brings true integration within reach. What's particularly encouraging is how accessible these technologies have become – from independent print shops to global converting operations, businesses of every size now have access to transformative potential. The UK packaging industry has always adapted and evolved to meet new challenges. Now, with AI becoming both more powerful and more accessible by the day, we're perfectly positioned to take that next decisive step towards a fully connected future.”

To learn more about Think B2B Marketing, please visit www.ThinkB2BMarketing.com.