From retail to manufacturing, artificial intelligence (AI) is having a transformative impact on various industries. This is expected to be an ongoing trend, with AI adoption delivering benefits such as improved efficiency, quality, and scalability. This applies particularly to the packaging of manufactured products, where AI is of growing relevance. We’ll explore the applications and key benefits here.
What is AI in Packaging?
AI systems enable the automation of tasks that have traditionally been carried out by people. This applies to the packaging of consumer goods, with AI being used for the creation of innovative and efficient designs. The integration of robotics and AI-powered machinery is becoming increasingly common, with packaging efficiency and accuracy being optimised. AI systems also allow for the adjustment of production, with businesses more able to produce and distribute packaged goods that meet particular demands.
There are various sector-specific examples of AI-driven packaging. The adoption of such systems is making for improved freshness in the food sector, with the assurance of tamper-proof seals and better shelf-life monitoring. AI-powered machines are also being used for the sorting, filling, labelling, and sealing of packaged goods in factories. AI enables smart packaging design too, with the use of materials, shapes and branding being optimised.
Other benefits of AI integration include:
- Improved detection of packaging defects and inconsistencies
- Increased scope to create customised packaging for individual customers and niche markets
- Reduction of material waste and operational downtime
- Optimisation of packaging design for minimal environmental impact
- Higher levels of customer engagement, with AI enabling the inclusion of interactive QR codes and augmented reality (AR).
AI in Factories: The Backbone of Smart Packaging
AI supports factory packaging processes in various ways. For instance, the integration of AI systems enables real-time monitoring and predictive maintenance of packaging machinery. AI can be relied on for the analysis of production data for the identification of inefficiencies and suggestion of improvements. Such data-driven decision making enables the optimisation of production schedules. Connected with IoT technologies, AI can also prompt automatic adjustments for the reduction of waste and improvement of packaging quality.
Robot-AI integration is becoming increasingly common, with manufacturers more able to automate packaging tasks in the dull, dirty, and dangerous categories. For instance in the USA, Coca-Cola has integrated AI-powered robots within its bottling plants for the automation of bottle filling, capping, labelling, and packing. AI has made for improved accuracy and efficiency, with the entire production line being monitored for quality control.
AI in Food Packaging: A Closer Look
Focusing on the packaging of food products, the integration of AI is making for improved safety and compliance. AI-enabled sensors allow for the more reliable detection of contamination and variations in sealing. Environmental factors such as temperature, moisture, and freshness can be closely monitored, with manufacturers automatically notified of any issues. Sustainable benefits are also being realised, with AI enabling the design of biodegradable and minimal-material packaging.
The food sector benefits have been highlighted in Machinery Update, with the January/February 2025 edition suggesting that automation may be the answer to retail demands for ready meal manufacturers (pages 32-33). For instance, Brillopak’s UniPAKer pick and place robot allows for flexibility in the loading of packaged ready-meals and processed foods into supermarket crates for delivery. A new line-side cobot has also been introduced, with the option of onboard vision to ensure that all of the necessary meal components are present.
Challenges in Adopting AI in Packaging
Of course, there are challenges to be overcome in the adoption of AI-driven packaging systems. While such systems are becoming more affordable, the upfront cost continues to be a concern for small and medium-sized companies. Time and money must also be invested for the successful integration and optimum use of AI systems. This should include the arrangement of workforce training, with employee concerns being addressed. Benefits in terms of safety and efficiency should be emphasised, with workers allowed greater freedom for tasks that make the most of their high-level skills.
AI-driven Packaging Predictions
Provided that such recommendations are followed, there’s every reason to believe that AI will continue to shape the packaging industry. Indeed, the global packaging market is predicted to grow from a value of $2.91 billion in 2025 to $4.51 billion in 2029, with a compound annual growth rate (CAGR) of 11.6%. This will involve the increased adoption of smart, connected packaging systems, powered by AI and the IoT. We can also expect to see the rise of fully autonomous factories with the integration of advanced robotics and automation. Other major trends will include the enhancement of consumer-focused packaging through machine learning and growth of AI-powered sustainable packaging solutions.
From efficiency enhancement to waste reduction and consumer satisfaction, there’s no denying the transformative potential of AI in packaging. You can look forward to exploring this potential at the PPMA Total Show 2025. Being held at Birmingham’s NEC from the 23rd to the 25th of September, this will provide the opportunity to discover the latest packaging machinery and design innovations. Go ahead and register your interest, today!