Packaging Machines: Where is the Automation Journey Heading?

The pressure to automate packaging processes continues to grow. Whilst information-driven processes often take centre stage in the packaging sector, the focus in mechanical engineering is increasingly shifting towards networking, automation and digitally supported process control.

This development is being driven by several factors simultaneously. A shortage of skilled workers, competitive pressure, sustainability requirements, a growing variety of product ranges and the need to react quickly to trends and regulatory requirements are increasing the pressure to act in many companies. Added to this is the fact that, particularly in e-commerce, both traditional high-volume orders and customised small batches must be fulfilled efficiently. The result: packaging machines must not only become faster, but above all more flexible and intelligent.

Automation as a Growth Driver

Customers of German packaging machine manufacturers are therefore investing increasingly in efficient and integrated line solutions to further boost productivity, flexibility and sustainability (see report from February 2026). “The signals from automation technology and the corresponding figures from the associations point to an upward trend,” reports Martin Buchwitz, Managing Director of Packaging Valley Germany e. V.  “The decision by many German packaging machinery manufacturers to focus on intelligent solutions offering high added value for customers, whilst not neglecting the mid-market, appears to be paying off.”

Two development trends are emerging particularly clearly: on the one hand, physical automation is gaining in importance, for example through robotics and more modular machine concepts. On the other hand, data-driven optimisation is becoming increasingly significant – that is, the ability to monitor conditions, analyse processes and proactively control interventions.

Pick-and-place is the leading segment in most robot categories within the packaging industry and requires precise handling and speed. The pick-and-place applications segment holds the largest market share, at 34.35 per cent in 2026. Furthermore, increasing advancements in sorting and packaging products for the e-commerce sector are driving demand for pick-and-place robots.

Cobots represent the largest sub-segment of the market, with a market share of 33.29 per cent in 2026. They offer a cost-effective way to automate repetitive tasks for small and medium-sized enterprises (SMEs), whilst larger manufacturers benefit from their modular deployment.

SCARA robots are on a growth trajectory due to their increasing use for high-speed and assembly tasks. They enable three-dimensional movements in production lines and improve productivity. According to the market study, demand for Delta robots and other robots with different gripper types will continue to rise due to their suitability for precise linear packaging and automated palletising tasks.

However, it is not so much the individual robot category that is decisive, but rather its function within the overall system. In packaging processes, robotics is increasingly shifting from individual workstations to integrated line modules in order to reduce manual tasks, simplify changeovers and manage changing product formats more flexibly.

At the same time, there is also a growing need for machines that can be quickly adapted to changing products, formats and batch sizes. This is because, particularly in markets with a high variety of products and short life cycles, rigid single-product lines are reaching their limits. There is therefore a demand for modular system concepts that enable cost-effective format changes and can be operated safely even by less experienced staff. Mechanical, electronic and digital support systems help to shorten changeover times, prevent errors and ensure the necessary flexibility during ongoing operations.

In practice, the benefits are most evident where transparency translates into concrete action. Modern machines are now often equipped with dashboards and connected to networks. Users can monitor their performance remotely, for example via an app. This is useful for analytical purposes, helping to identify productivity issues. The same applies to individual machine components such as motors: if, for example, their power consumption increases noticeably, this may be due to a fault or another malfunction in the system. Remote maintenance allows such anomalies to be detected at an early stage. This enables manufacturers or operators to react in good time and provide replacements before breakdowns occur.

Sustainability and Regulation as Additional Technology Drivers

Automation is also driven by sustainability issues. It is no longer merely a matter of packaging materials, but is increasingly influencing machine and line development. Companies are under pressure to reduce material usage, energy consumption and waste, whilst at the same time aligning their processes with recyclable and resource-efficient packaging concepts. Automation is thus also becoming a tool for making sustainability goals economically viable.

This development is receiving a further boost from regulatory requirements such as the EU Packaging and Packaging Waste Regulation. It increases the pressure to technologically overhaul packaging processes and, in particular, to address material efficiency and the reduction of empty space more systematically. In e-commerce and product shipping in particular, automated solutions for precisely fitting packaging are therefore coming increasingly into focus. On-demand systems for customised corrugated cardboard boxes, for example, can help to reduce filling material, transport volume and material consumption without compromising protective function or logistics efficiency.

Prerequisites and Limits of Development

As clear as the direction may be, the journey towards automation is far from straightforward in practice. Many packaging environments have evolved over time and are characterised by different generations of control systems, heterogeneous machine fleets and various manufacturer systems. This diversity complicates end-to-end connectivity and, consequently, the meaningful use of data for advanced automation and AI applications.

Furthermore, digital systems in an industrial environment must operate reliably and transparently. Unlike in purely information-driven applications, plausible results are not sufficient in mechanical engineering; what is crucial are validatable data sources, defined interfaces and reproducible results. Only once these foundations have been laid can the benefits of AI, diagnostics and data-driven optimisation be reliably utilised in practice.

It is precisely here that the true benchmark for the next stage of automation lies: companies that specifically combine physical automation and data-driven optimisation create the conditions for making packaging processes more robust, economical and adaptable. The automation journey thus leads not to isolated high-tech machines, but to integrated, adaptive and flexibly controllable packaging processes.

Author: Alexander Stark, Editor, FACHPACK360°