The New Era of Packaging Automation: Smarter, Faster, More Flexible

Packaging automation is experiencing one of the most dynamic shifts in its history. What once centered on improving efficiency and reducing ergonomic strain has expanded into a full‑scale transformation of how manufacturers keep production lines running, maintain quality, and scale for growth. According to Mike Brewster, Vice President of Sales at Pacteon Group, one thing is clear: automation is no longer optional — it’s essential.

Schneider, a long‑established leader in end‑of‑line packaging solutions and a key part of the Pacteon Group, has been integrating robotics into its equipment for decades. Today, Brewster sees a new urgency across the industry as manufacturers rethink how they approach labor, throughput, and flexibility.

Automation’s Growing Strategic Role

For years, the appeal of automation centered on three priorities: reliability, repeatability, and the ability to reallocate workers to safer or more value‑added roles. But in today’s environment, manufacturers are facing increased pressure to keep lines fully operational regardless of workforce fluctuations.

As Brewster notes, “Manufacturers are looking to automate any process that’s currently manual to keep their lines running and get product out the door.” Many facilities simply cannot find the staff to perform repetitive, physically demanding tasks — a challenge that has pushed automation from a long‑term goal to an immediate necessity.

And the traditional concept of return on investment has shifted too. Brewster explains that manufacturers need solutions that deliver business impact right now. “What companies need is the ability to get product out,” he says. “There are lines that are non‑operational simply because the staff required to operate them isn’t available.”

Where Automation Is Delivering the Biggest Impact

Among all end‑of‑line operations, palletizing stands out as the area seeing the fastest and most widespread adoption. Many producers who invested early in automation for filling, cartoning, or labeling still relied on people to manually stack heavy cases — a task that is both ergonomically risky and hard to staff consistently.

“It's difficult to find and retain employees to manually stack 60‑lb boxes consistently onto a pallet,” Brewster says. Robots solve that challenge decisively, offering consistency that manual labor simply cannot match.

Brewster highlights the data behind the shift: “When you look at the numbers, there’s no contest. The mean time between failures is around 80,000 to 100,000 hours, and the quality is consistent.” As he puts it, “If I were hand‑stacking product for an 8‑ or 10‑hour shift, my quality and output would deteriorate. That doesn’t happen with robots.”

Beyond performance, robotic systems also enable scalability that manufacturers struggle to achieve through hiring alone. Brewster frames it this way: “If your goal is to produce 20% more product this year, are you going to hire 100 people — or deploy 10 robots that could be up and running in six months?”

The Next Frontier: AMRs and AGVs

While automation within the packaging cell has become mainstream, manufacturers are now looking to extend automation downstream as well. Brewster sees the next major growth opportunity in autonomous mobile robots (AMRs) and automated guided vehicles (AGVs).

Instead of relying on forklift drivers to move wrapped pallets into warehouses or onto trucks — another role that is increasingly difficult to staff — manufacturers are exploring fully automated material‑handling ecosystems.

“Customers want a completely automated process,” Brewster explains. “That’s going to be a huge area of growth for our industry.”

Breaking Down Barriers to Adoption

Despite its clear advantages, many companies still assume automation is prohibitively expensive or too complex for their workforce. Brewster believes those concerns are outdated.

“There’s a preconception that automation is extremely expensive,” he says. “But the industry has come a long way, and the barrier to entry is much lower than it was even a few years ago.” This is especially true with collaborative robots, which offer cost‑effective automation for lighter payloads and lower‑throughput applications.

Concerns about operator skill levels are also diminishing thanks to intuitive interfaces. As Brewster puts it, “If you can operate an iPhone, you can operate our equipment.”

How Manufacturers Can Prepare for Automation Success

Success depends on choosing the right partner — one with experience, certifications, and a track record of safe and effective implementations. Schneider meets these expectations as a FANUC authorized system integrator, a Rockwell machine builder, and a manufacturer that adheres to Robotic Industries Association (RIA) standards.

Beyond partner selection, Brewster emphasizes the importance of evaluating facility layout and material flow. “Even small equipment takes up room,” he says. “You need to understand how a robotic cell will impact the movement of materials and people throughout the plant.”

Building Flexibility Into Automated Systems

Modern packaging environments change quickly, and Schneider designs its systems with that in mind.

One key example is OptiStak, its proprietary pallet‑generation software co‑developed with FANUC. “With OptiStak, you can add a new recipe in minutes right from the HMI,” Brewster says. What once required technician assistance or onsite visits can now be handled instantly by plant personnel.

Schneider’s case packers are also engineered for a broad range of sizes rather than a single case dimension, ensuring long‑term adaptability. And its dedicated aftermarket team helps customers evaluate packaging changes before they are finalized to avoid costly retrofits.

Automating Changeover With ProAdjust®

Another Schneider innovation gaining strong demand is ProAdjust®, the company’s automated machine‑adjustment system. Brewster highlights both its consistency and practicality.

“With a simple press of a button, the machine adjusts to exactly where it needs to be,” he says. This ensures reliable changeovers across shifts and eliminates the variability that comes with manual adjustments — variability that compounds quickly in fast‑paced environments.

A Competitive Edge Through Robotics

For Brewster, the value proposition is clear. “Robotics provides a competitive edge through repeatability and reliability in areas that manual labor just cannot match.” And as manufacturers continue facing intense pressure to maintain output, automation will remain central to their strategies.

Schneider’s goal remains straightforward: to provide the solutions and support that help customers stay competitive — not just today, but well into the future.

Mike Brewster

VP Sales, Pacteon