The packaging industry is well-known for being dynamic and innovative. Equipment suppliers and end users have always embraced opportunities created by new technology and market demands. Looking ahead, there are multiple issues which will drive packaging technology forward in the years to come. Here we look at five key trends in packaging technology which will continue to give our sector an important presence at the heart of UK industry.
Flexibility
An overriding theme for businesses to consider for the coming years is flexibility. It is increasingly being recognised that the concept of a facility which does only one thing is fast losing relevance. The world is moving too fast to tie up investment and resources in a capability which may no longer be required because of significant changes in the market, technology, regulations and world events.
Flexibility in packaging machinery ranges from the ability to handle different sizes and types of products, to being able to reconfigure a packaging line by using modular units which can quickly and efficiently be used to perform different work. The ability to link modular units with conveyors or by AGVs (automated guided vehicles) or AMRs (autonomous mobile robots) is one of a range of ways towards truly flexible work environments.
Programmable controls also add flexibility and make changeovers faster – they are an increasingly important element in machinery specifications. Beyond programming, machine learning and AI (artificial intelligence) adds to the way that packing operations can be designed to remain relevant to the changing demands of the packaging industry.
Automation, Robotics and Vision Systems
Many packaging businesses, if they had a free hand on machine investment, would aim for complete solutions that reduce labour, increase efficiency and maximise output. Fully automated packaging systems with technologically advanced controls are an extremely attractive prospect.
The value of automation is universally recognised by operational managers and finance chiefs, and continues to be bedded into the plans of most packaging companies. Automation solves many problems for organisations including:
Availability of good staff
Lower labour requirements are particularly attractive at a time when recruiting staff is a challenge for many organisations.
Staff costs
Lowering the wage bill without losing productivity is a big plus on the balance sheet. Alternatively, where automation frees up staff, businesses can benefit from redeployment in profit making roles such as research and development.
24/7 operation
Keeping machinery running for the maximum amount of time gives the best return on investment. Automated machines don’t need time off or overnight shut downs.
Productivity, accuracy and spoilage
Automated equipment runs faster than any processes requiring manual operation, and is also more accurate, meaning less spoilage.
In the real world, total replacement of existing machinery is not always economically viable, and investment centres on specific elements of a packaging operation. An area which attracts many buyers is robotics, with new robotic equipment being integrated into existing operations. For example, a robotic arm could be installed which could improve pick and place operations. The capabilities of modern delta robots are improving all the time, for example in being able to handle items as delicate as raw eggs and feather-light vol-au-vent cases. Further examples include end of line work, such as dramatically improving palletising operations.
A growth area of robotics will continue to be cobots which work in partnership with human staff. Cobots are perfect for taking over repetitive, tedious and physically demanding tasks, leaving employees to manage processes and to undertake work which cobots cannot do, such as clearing obstructions or fixing component breakdowns. Increasingly, cobots are coming to market which are compact, safe, flexible and relatively affordable.
Accurate controls are at the heart of automation, and the role of ever more capable vision systems are key to machine control, measurement and inspection. The move towards stereo vision allows extremely detailed monitoring of processes while they are running, and examination of any flaws in finished products and packages. X-ray vision systems are increasingly important for highly accurate examination of package contents and product batches. Modern vision systems can also eliminate the need for manual code validation and inspection, with the capability to reduce false rejection rates. Vision systems are also behind the rise of AGVs and AMRs in particular, giving them the ability to work around obstacles.
Automation and associated robotic and vision equipment were once the exclusive preserve of major businesses, notably automotive manufacturers. However, as the supply of equipment advances, including modular units, these key types of equipment are coming increasingly within reach of smaller businesses. It’s a trend to keep watching, because opportunities will arise for organisations of all sizes throughout the packaging sector.
Environmental responsibility
The green agenda has been gaining prominence over many years, and is being driven further forward by extreme weather events which testify to global warming. Arguably the world has been on the brink of an energy crisis for decades, but it now comes into sharper focus with disruption to energy supplies through political events and conflict. Environmental responsibility is a priority for businesses because of:
- Consumer attitudes
- Regulation
- Reputation
- Reduced resources
For packaging that means introducing new processes and approaches which deal issues such as:
Void fill
Reducing void fill in cartons and other containers allows carriers to transport a greater number of smaller packs in vans, lorries and containers. It also reduces the need for packing material which traditionally has included polystyrene chips and bubble wrap. Void fill materials are increasingly moving towards recyclable and recycled papers and boards.
Lightweighting
Reducing the thickness of glass, the weight of cardboard and the density of plastics all reduce the overall tonnage of material taken from packaging facilities to end users. As a result, there is a reduction in energy used for transport, and less material needs to be recycled or go to landfill.
Returnable and reusable packaging
Returnable packaging dates back to the days of returnable glass bottles for milk, beer and other drinks products. The approach is resurging with reusable packaging now in use at dedicated refill shops, and is making an appearance in mainstream supermarket and High Street stores as well.
Biopackaging
While recycled and recyclable plastic packaging materials are in widespread use, there is a growing trend for biodegradable and compostable wrapping, trays and containers.
Biodegradable materials are plant-based products such as wheat and corn starch which are broken down slowly by bacteria and other organisms. Biodegradable papers, cartons and corrugated board are increasingly available. By contrast, degradable packaging cannot be broken down by living organisms but disintegrate into smaller and smaller particles to become minute microplastics which are now recognised as a threat to all manner of marine and land environments. Compostable packaging breaks down naturally and leaves no toxic residue is also on the rise.
Monomaterials
Composite materials which combine recyclable and non-recyclable elements present a problem because, without the ability to separate the components, they can generally only be treated as landfill. The challenge for packaging companies is to find monomaterials which can be entirely recycled but which also have the same performance characteristics as composites for sealing, forming barriers and printing. New developments in bags, pouches and tubes are showing the way forward for the monomaterial packaging trend.
Regulations
A new marker for the way regulations will increasingly impact the packaging industry came
in April 2022 with the advent of the UK government’s Plastic Packaging Tax. The new tax results in a charge of £200 per metric tonne on all plastic packaging components that do not contain at least 30% recycled material. The intention is that the tax will create a drive towards more environmentally friendly packaging.
Businesses need to take advice and keep abreast of the regulatory environment. PPMA publications and the PPMA Showcan be a helpful resource for members to find out about the latest developments.
The rise of ecommerce
Ecommerce is now so deeply established in the retail sector it merits as much focus as store-based retail. The UK is the third largest user of ecommerce in the world, behind the massive online markets in the USA and China. Over 35% of UK retail sales are made online.
In the past packaging operations for retail products may have centred on bulk distribution to central retailer warehouses for onward bulk distribution to stores. By contrast, ecommerce deliveries to the home are for individual items or small groups. The types of packaging are advancing all the time, with an estimated 90% of items shipped in cardboard boxes void filled with elements such as scrunched up kraft paper, polystyrene pellets, air-filled pillows or bubble wrap. Cartons also rely on extensive use of tape.
The ecommerce trend is certain to continue, even if the rate of growth of the sector slows down. Ever more innovative packaging trends will emerge to cater for efficiencies, environmental issues and customer experience. Innovative approaches include packaging which fits through the letterbox, including wine and dishwasher tablets. The trend in ecommerce towards flexible packaging has seen a move to pouches instead of heavier jars and bag-in-box drinks replacing glass bottles.
Ecommerce businesses are acutely aware of their reputations, and are determined to avoid the laughable amount of cardboard and void fill used in the past to deliver tiny products. Look out for plenty of developments in minimalist packaging technology.
A focus on customer experience will also increasingly generate innovative ways of branding packs and engaging ecommerce customers. Pack design will increasingly incorporate access to interactive online experiences through QR codes, and scannable links to augmented reality and virtual reality brand experiences. The days of simple cardboard boxes are numbered.
Where to find out more about packaging trends
PPMA sets out to keep members and other businesses firmly in touch with what’s new in packaging. The annual PPMA Show is an exceptional opportunity to meet a wide range of innovative packaging machinery suppliers, and to network with industry peers. PPMA Machinery Update features the latest news and developments, and machinery buyers also have a valuable resource in PPMA Machinery Finder, a comprehensive guide to suppliers, with company profiles, web links and contact details.
