Innovation in the Packaging Industry: How Robotic Packing is Arming Companies for the Future
The packaging industry as a whole has never been shy about adopting the latest technology. With so much product on the move—from vegetables, to pharmaceuticals, and everything in between—this business literally never sits still.
The first robotic packing machines went to work in the mid-1980s, when robotic top-load case packers and palletizers hit warehouse floors. Just a decade later, vision-guided packing automation represented a huge upgrade.
And it hasn’t slowed since. Here’s a look at how the industry is poised to continue growing, and how robotic packing is revolutionizing it as it grows.
The Packaging Industry is Booming
Most industries rely on the packaging industry in some way. As e-commerce continues to grow, so too does packaging.
- Globally, the packaging market is set to expand by almost 3% per year, reaching over $1.2 trillion by 2028.
- Food packaging alone is expected to grow from $505.27 billion in 2024, to $808.40 billion by 2032.
The growth represents increasing demand on quality, efficiency, and ROI. As processes advance, the need for worker safety and versatile packaging machines will also come to the fore.
Fortunately, the solution is ready and waiting. Robotic packing can deliver speed, accuracy, safe working conditions, ROI, and the flexibility that growing companies need.
Increased Speed
Robotic case packers are exponentially faster and more efficient than manual packaging assembly lines.
How fast depends on a variety of factors, including how much of the process is automated, how big the cases are, how delicate the product, etc. A top-loading delta robot, for example, can pick and place up to 80 items per minute.
Any packaging robot assembly is going to move faster than a team of human packers—and for longer stretches of time. Not only are robots faster, they also don’t need breaks.
Flawless Accuracy
With manual packaging lines, speed and accuracy are often at odds, but not with robotic packers. Automated case packers use multiple systems to count product, package items in cases, weigh boxes, etc.
It’s also worth noting that packaging robots don’t make mistakes due to fatigue or other external influences.
Improved Safety
Manual assembly lines and warehouse environments can be physically demanding and introduce workers to a variety of hazards. One of the most conclusive ways to improve worker safety is to offload the tedious, repetitive work of case assembly and packing to robots.
Different robots and machines have a variety of safety features including gates and walls that enclose moving parts, emergency shut-off switches, safety covers, and more.
ROI
Robotic case packers are primarily revolutionizing the packing industry by dramatically improving ROI. Any piece of equipment is an investment, but with exponentially faster speeds, more consistent work times, fewer mistakes, and a more streamlined payroll, packaging machines are an easy decision.
Packaging robots pay for themselves quickly, and once the investment is covered, the profit margin becomes unbeatable.
Versatility
The latest robotic arms and packing machines are often specifically designed for versatility. With flexible mechanical design and user-friendly operations, case packing robots can be easily configured and programmed to perform a variety of tasks—with the same speed and accuracy.
Many packaging machines use gantry, delta, and PKR robot arms to optimize this versatility. These robotic arm designs can effortlessly adapt to different product types, sizes, packaging, formats, product requirements, and more.
The Latest Innovations in Packaging Robots
Pick and place robots have been coming to work for decades, but the future of the packaging industry is being defined by some of the latest advancements.
Pick & Place Product Loader
Pick & place product loaders are designed for high-speed, precise product placement, excelling in automatically feeding products onto conveyors before the flow wrapping process with exceptional accuracy.
Where traditional loaders might struggle with speed or handling delicate items, the PKR Scara ensures consistent placement, reducing waste and product damage. Its compact design makes it versatile enough for a wide range of applications, from food to pharmaceuticals, all while maintaining the precision that’s essential for modern packaging lines.
Top, Side, or Bottom Loading
Packaging systems have evolved to automatically pack various types of products, offering flexible solutions for different packaging needs.
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- Top-load applications are the most common, and suitable for almost any kind of container or product—from jars, to bags, to clamshells, and more. These systems may use robotic arms or automatic gravity-drop packaging.
- Side-load machines automatically erect a case and push materials in from one side. These systems are ideal for delicate products, heavier cartons, or small containers of liquid.
- Bottom-load machines are similarly suited for products that are difficult or too delicate to grab from the top. These systems are often used for heavy or fluid-filled products.
End to End Systems
Robotic case packers can be implemented at any stage of the packaging process to improve efficiency, speed, and safety.
Semi-automatic systems, for example, can accelerate and automate some steps, while leaving others to manual workers. One popular option is a semi-automated robot packer that erects cases and seals them, leaving a length of conveyor in the middle, where operators manually fill the cases.
True innovation and optimal ROI are achieved, however, at full-scale, end-to-end automation.
Automatic robotic packing machines can be designed for any application. They can fill primary packaging with product, erect cases, package finalized product, visually inspect for accuracy, and seal packaging for shipment.
Innovative Use Cases: Robotic Packing by Industry
Packaging automation is so advanced and versatile, that it’s advancing most industries that have embraced it.
- The food and beverage industry has strict requirements for sanitation and hygiene. Packaging and equipment must be commercially sterile, and machines need to be easy to clean. Packing robots help maintain cleanliness standards, and some are even designed specifically for sanitary applications. This includes sectors such as snack foods, bakery products, meat and poultry, and fruit and vegetables.
- Pharmaceutical brands have turned to packing robots as the precision of pick-and-place robots, check weighing, and vision inspection has advanced to meet the industry’s stringent needs.
- The growing e-commerce market continues to drive demand for packing products of all shapes and sizes. Innovative pick-and-place robots and user-friendly software have made packing robots flexible enough to handle a wide variety of applications, including home goods, hardware, and pet food.
Robotic packing has even found its place in industries like cannabis, where precision and compliance are critical in packaging and handling products safely and efficiently.
The Future of the Packaging Industry is Robotic
The packaging industry is always evolving and staying competitive means keeping up with standards and trends. The speed and accuracy offered by robotic case packers is unmatched.
Ready to take your packaging processes to the next level? Whether you’re just getting started with automation or you’re ready to upgrade a partial system or to integrate downstream automated packaging machines with your existing automation, the expert team at Paxiom can help you figure out the best next step.
Give us a call at 1.833.4PAXIOM or get in touch online, today!