A Comprehensive Guide to Packaging Automation

Streamlining production, packaging, and shipping is paramount for businesses. Not only buying product packaging from a reputable company is necessary, but packing products suitably in it is also needed.

Packing manually is always hectic, and requires significant labour costs. The risk of errors is also high if the packing process is manual. That’s where packaging automation comes into play. Using machines and robots to pack products is becoming popular in the packaging industry.

Automated packaging processes help optimise the supply chain, reduce logistic costs, and bring many more. In this blog, we will discover everything you need to know about packaging automation. Read on to find more!

What is Packaging Automation?

Packaging automation is the process in which tedious tasks of packing products, and sealing boxes are transferred to automated systems. These systems are designed in such a way that they can pack products in large quantities without the need for manual labour.

The importance of packaging automation is increasing in e-commerce, logistics and retail companies. The reason is that these businesses are required to streamline their supply chain, and automated systems help them do so.

With the help of robotics and machine learning, various machines have been designed that help automate the packaging process. This approach streamlines the supply chains without much effort and at a minimal cost.

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5-step Packaging Automation Process With Robotics

• Product Reception and Identification
• Sorting and Orientation of Packaging
• Product Packing and Cushioning
• Sealing and Labelling
• Quality Check and Verification

Role of Robotics in Packaging Industry

Now that we know the importance of automation in the packaging industry, let’s explore how robotics help in the automation of packing boxes, bags, bottles, etc. The demand for industrial robots is rising when it comes to packaging automation.

According to research shared by Future Market Insights, the global market volume of robotic packaging machines has increased at 4.2% CAGR from 2020 to 2022. With consistent development in technologies like machine learning, more innovations in automated packaging can be foreseen.

If you want to make your packaging process more streamlined, let the robots handle most of the hectic tasks. The reason is that robots handle repetitive tasks precisely and minimise human efforts as well as errors. Robotic automation can also reduce product contamination risk by reducing human intervention.

However, handing the entire packaging process (from manufacturing boxes to filling and sealing them) to robots can be expensive. Combining the cost of production, die-cutting, printing, filling, and sealing may burden your budget if you are a small business.

You can streamline your packaging process with automation if you outsource the production and packaging customisation to a reliable company. OXO Packaging, for instance, takes the full responsibility of personalising your boxes, bags, and bottles for product packaging.

We customise your packaging such that it is supported by your automated packing or filling system system. For instance, we can make custom mylar bags for food storage that can be heat-sealed with an auto-vacuum packaging machine.

5 Major Advantages of Automated Packaging Solutions

Automation does much more than eliminate the tiresome efforts to carry out the packaging process. Here are 5 major benefits that make automated packaging solutions the first choice of e-commerce, logistics, and retail businesses:

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5 Packaging Automation Benefits

• Improved Quality Control
• Optimised Supply Chain 
• Better Ergonomics
• Sustainable Practices
• Lower Logistic Cost

• Improved Quality Control

Automated packaging can help a lot when it comes to maintaining the quality of their items. The streamlined packing and sealing process removes the chances of errors. It ensures the items packed in boxes, bags or bottles remain in the best of their quality.

For example, packing medicines in pharmaceutical packaging requires extra care. The reason is that medicines go to waste if even a minor change in their composition takes place. An automated system is designed such that it perfectly packs the medicinal drugs without exposing them to environmental contaminants.

Such systems have sensors that can detect the changes that occur in medicine. Automated packaging also helps you in efficiently labelling the pharmaceutical boxes for compliance.

 

• • Optimised Supply Chain 

  Inappropriate supply chain management results in unnecessary delays and cluttered operations. Automation in packaging helps streamline your supply chain without hassle.

  Integrating robotics in your packaging automation helps you cater to all your packaging needs (except for the production of packaging). From stacking boxes, bottles, and bags to filling and sealing them, automation does everything without the need for manual labour.

  When it comes to bottle filling, some automated systems can add bottle neckers as well before capping the bottles. This means this system makes your product ready to sell in the market.

  The best part is that what is done in many days, these machines do in hours. Using machines can ensure a hassle-free supply chain if you go for automated packaging.

• Better Ergonomics

In a manual warehouse packaging environment, space optimisation is important. Items, labour, tools and packaging boxes require significant room. Having a wide space just to pack your products can cost you a lot.

However, choosing automated solutions can lead to a significant reduction in packing stations required within the warehouse. It allows businesses to create an ergonomically well-optimised working environment minimising the hassle and reducing warehouse rental cost.

• Sustainable Practices 

The significance of sustainable practices is increasing these days. The reason is that customers prefer to buy products that are packed in a sustainable packaging solution.

Packaging automation not only speeds up already existing packing processes but also reduces waste. These systems can measure a box, bottle, or bag against the dimensions and quantity of products within it. This measurement helps them use appropriately sized packaging to pack products that reduce waste.

Some large-scale automated systems are incorporated with bins that collect the recyclable material. The materials these systems collect can be recycled and reused instead of going to waste.

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Sustainable Packaging Automation

• Promote Recyclability
• Reduce Waste
• Reusable Packaging Designs

Sustainable Practices The significance of sustainable practices is increasing these days. The reason is that customers prefer to buy products that are packed in a sustainable packaging solution. Packaging automation not only speeds up already existing packing processes but also reduces waste. These systems can measure a box, bottle, or bag against the dimensions and quantity of products within it. This measurement helps them use appropriately sized packaging to pack products that reduce waste.

Some large-scale automated systems are incorporated with bins that collect the recyclable material. The materials these systems collect can be recycled and reused instead of going to waste. Infographic Copy Sustainable Packaging Automation Promote Recyclability Reduce Waste Reusable Packaging Designs

• Infographic Copy

  Sustainable Packaging Automation

• Promote Recyclability
• Reduce Waste
• Reusable Packaging Designs

• Infographic Copy

  Sustainable Packaging Automation

• Promote Recyclability
• Reduce Waste
• Reusable Packaging Designs

5 Types of Packaging Automation Machines

As discussed before, packaging automation is made possible with machine learning and robotics. Various automation machines are available to help you streamline the product packaging processes. Here are the 5 most popular packaging automation machines:

1. Filling Machines

Filling machines are used to automate the packaging of liquid or powdered items. When it comes to liquid products, filling machines fill based on their volume. Liquid filling machines automate the filling of bottles, cans, and cups such that an equal volume of product is filled in every unit.

Powdered products also need to be filled in the packaging. To do so, automated machines measure the weight of the products. The process used to pack powdered products is called spiral filling. This process helps match the weight of the product with the volume of the packaging.

Capsules and tablets can also be filled in bottles. To fill these items, the machine measures the quantity of product in numbers. Each bottle contains an equal standardised number of capsules.

 

• Flow Wrapping Machines

A flow wrapping machine is used for wrapping products. These machines pack products in polyethene or polypropylene wraps. Both types of wraps are flexible and ensure the nug fitting of products. The process of flow wrapping is common for the name of horizontal bagging, or pillow pouch wrapping. Here is a step-wise process that flow wrapping machines follow to wrap your products: Select and place items to be packed in the conveyor belts.

Wrap a manually-fed sheet of polythene or polypropylene around the product. Align the edges of sealing sheets. Heat or pressure-seal the aligned edges of the wraps. Move wrapped products to cutters that cut attached items to separate them. Transfer the final wrapped products to the storage where they can be stacked manually.

• Cartoning Machines

Packaging cartons like custom cardboard boxes are mostly used as secondary packaging for many products. Enclosing items snugly in these cartons can be an uphill task if done manually. An automated cartoning machine can be used as a proficient alternative to manual packing.

There are two types of cartoning machines used commonly. The first one is a horizontal cartoning machine, which packs products that are easy to stack such as cereal packaging boxes. The other one is a vertical cartoning machine; excellent for difficult-to-press products.

A cartoning machine caters to the packaging process from start to end. Put simply, machines do everything from folding the cartons and arranging products inside them to closing and sealing them.

• Vacuum Packaging Machines

Vacuum sealing is the process which helps take the air and oxygen out of the packaging. Machines for vacuuming are primarily used for food packaging. The reason is that this process keeps the food items fresh for a long time.

For instance, these machines are excellent for mylar bags for food, as these bags of vacuum sealed enhance the shelf-life of food.

The vacuum packaging machine comes with a packing unit that packs products in the appropriate portion inside the packaging. Afterwards, the packed (but not sealed) items are transferred to vacuuming units. These units extract air from the bags and bottles and then seal them with pressure-heating or other mechanisms.

Tidbit: Heat-sealing is ideal for storing products in vacuum mylar bags.

• Bottle Capping Machines

Bottle capping is necessary for closing and storing liquid and many other products. For bottled products, capping machines help streamline the packaging process. These automated machines come with cap-closing units that securely close the bottles. For sealing purposes, caps with pre-installed seals are pressed on the top of bottles.

Two types of automation machines are used for bottle capping purposes. A fully automated one requires zero manual effort for closing bottle caps and stacking bottles. On the other hand, a semi-automatic machine requires manual effort for stacking and packing bottles and capping.

These automated systems also help you comply with the new decision of the European Union against plastic waste:

“All plastic bottle caps are mandated to remain attached to bottles starting July 2024.”

Consumer Trends Affecting the Future of Packaging Automation

The exponential increase in the usage of automated packaging systems can be witnessed. The reason is that automated systems not only provide convenience to businesses but also resonate with modern needs.

Here are some consumer trends that have resulted in high demand for automated packaging in the market:

• Users prefer to use products packed in sustainable packaging. According to a report shared by PR Newswire, 82% of consumers are willing to pay more for products packed in sustainable packaging. As packaging automation reduces waste, it is a sustainable practice to follow.

• Buyers pay significant attention to the aesthetics of unboxing when they buy a product. An automated system ensures fine creasing and designing of the boxes that enhance the unboxing experience when users open the packaging.
• Consumers always want the products in stock, so they can buy whenever they need. Especially when it comes to FMCGs, items getting out of stock create a negative impression on customers. Packaging automation helps streamline your supply chain and meet the needs of your buyers.

Automation in Food Packaging

Automation in food packaging is getting more popular due to its undeniable benefits. According to Global Newswire:

“Food packaging automation is exhibiting a solid CAGR of 7.8% from 2023 to 2032.”

From filling and labelling to sealing and monitoring, automation helps make the food packaging process easier in many ways. Starting with the filling, automation helps you pack items in accurate portions. It helps in standardising the quantity of foods in packaging.

Labelling and sealing are also important parts of food packaging. Both can be done automatically with the help of machines that reduce labour costs and minimise the chances of errors.

Product safety is one of the biggest concerns of food sellers. Automation helps remove the risk of contamination. Also, many automated systems are incorporated with sensors that monitor the freshness of food items helping them calculate the expiry date with high accuracy.

Conclusion

This is it about packaging automation! From the definition to undeniable benefits, we hope you know everything about packaging automation now. Choosing automated packaging can bring you a lot of benefits and is a recommended practice to manage your supply chain.

However, if you don’t want to manage the huge expenses of packaging automation processes, you can still manage your supply chain without spending extra. Get in touch with OXO Packaging to customise packaging as per your needs. Shoot us an email today to discuss your packaging requirements.