Packaging robots - why implement them and how to prepare your business for the future

Estimated reading time: 10 minutes

TL;DR:

• Automated packaging processes translate into shorter lead times
• Packaging robots increase repeatability and eliminate human error
• Support team safety and ergonomics
• Allows a flexible response to changes in demand and product diversity
• Can pay for themselves financially in as little as 1.5-2 years

Table of contents

• Introduction
• Key benefits of implementing packaging robots
• Main areas of application for packaging robots
• What does the implementation of packaging robots look like in practice?
• Current market trends in packaging automation
• The most common challenges in implementing packaging robots
• Who benefits most from packaging robots?
• Case study: increasing competitiveness in a medium-sized company
• Packaging robots in the offer of Michale Automatics
• How do you start preparing for the robotisation of packaging?
• Development perspectives and final conclusions
• Practical tips - summary
• Completion
• FAQ

Introduction

Packaging robots have grown strongly in popularity in recent years, becoming one of the most important drivers of efficiency for manufacturing companies. According to the latest figures, as many as 92,393 new installations of industrial robots have been recorded in Europe by 2023 - a record result showing how large the scale of automation is today. Michale Automatyka, as a company specialising in the construction of machines and the integration of robotic workstations, is observing this trend not only in the Polish market, but also throughout the European Union. In this article, you will learn why packaging robots are so important for companies betting on growth, the benefits of their implementation and how to best prepare for the packaging automation process.

Key benefits of implementing packaging robots

Efficiency gains and cost reductions

The robots can operate continuously, eliminating the interruptions associated with workers having to rest. This allows companies to significantly increase the volume of products packaged per day. At the same time, thanks to full automation, we are able to reduce errors related to the human factor (e.g. labelling errors or inaccurate package closures), which directly translates into lower costs related to complaints or corrections.

Improving quality and repeatability

Packaging robots - whether smaller cobots or advanced machines with larger payloads - perform each task with the same parameters and pressure. This makes it possible to achieve a reproducible quality of the final package. In high-precision industries (such as food or pharmaceuticals), consistent quality and a consistent product appearance are key to building credibility with customers.

Employee safety

One often overlooked aspect of robotic packaging is the safety of workstations. Traditional packaging processes can be tiring and carry a risk of injury (e.g. when lifting heavy components). Robots take over the most stressful duties, thus reducing the number of injuries and accidents on the production floor. Employees can therefore tackle tasks that require greater flexibility or creativity, which also translates into higher job satisfaction.

Flexibility and scalability

Packaging robots today are not just machines designed for a single process. The increasing availability of sensors, vision systems and integration software makes it relatively easy to reprogram such machines for different tasks, e.g. to handle packages of a different shape or size. Scaling up the business thus becomes much simpler: when demand increases, it is enough to change the robot's operating parameters or add another module, instead of investing in a completely new production line.

Main areas of application for packaging robots

Sorting and packaging of products

Robots excel at sorting a wide variety of objects, which is particularly important in the food industry (vegetables, fruit, snacks) and e-commerce (small parcel logistics). Sensors and vision systems enable shape and colour recognition, and appropriately configured grippers adjust the force applied so as not to damage the packaged product.

Packaging in bulk

In the FMCG (Fast-Moving Consumer Goods) industry and in many manufacturing industries, the focus is on the rapid packaging of large quantities of goods in bulk packaging. Packaging robots are ideal for such applications due to their speed and precision. Automation reduces the risk of product damage, for example when packing cups or other fragile items in cartons.

Palletisation and depalletisation

Although palletisation is sometimes considered as a separate production step, it is often combined with the final packaging process. Packing robots can not only put products into cartons, but also complete the finished pallets and prepare them for shipping. For companies with large-scale production, this is an essential part of internal logistics. Implementing a single robot capable of handling this entire process avoids duplication of company resources.

What does the implementation of packaging robots look like in practice?

Process audit and solution selection

The first step is a detailed analysis of what is happening on the production line. Questions need to be answered:
- How large and varied are the product series?
- Is the packaging process subject to frequent changes (e.g. different packaging specifications for export markets)?
- How large is the production space to be developed?

On the basis of such an audit, a robot with the right lifting capacity, reach, vision functions and the right control software is selected. Often test pilot projects are implemented, in which integrators such as Michale Automatyka verify that the proposed solution actually meets operational requirements.

Integration into existing systems

Whether the robot is to interface with an MES, ERP or other automation solutions, proper integration is a key element of success. If the company uses an advanced production tracking system, it is essential that packaging robots send or retrieve data in real time. It then becomes possible to automatically adapt packaging parameters to current line conditions (e.g. different product type on the next shift).
Many companies fear that the implementation of packaging robots will cause prolonged downtime and upset the entire production sequence. However, the Michale Automation team, with its experience in implementing robotic workstations, can plan the work schedule in such a way that production is not stopped for long. Some of the implementation stages, including testing and assembly of mechanical components, can be carried out during hours with less load on the line.

Employee training and service support

Even the best selected and integrated packaging line requires ongoing maintenance and optimisation. This is why it is so important that the plant's employees receive adequate training. These concern both the daily operation of the robot and the maintenance of safety procedures.
In addition, it is useful to have access to fast service or remote diagnostics, especially if the packaging robots operate on a 24/7 model. In the event of any breakdown, immediate response and technical support becomes crucial. If you are looking for service for robotic workstations, it is worth checking out the offerings at Service and maintenance stands.

Current market trends in packaging automation

Growing popularity of cobots

Cobots (cobots, or collaborative robots) are becoming particularly attractive in smaller production facilities and in areas where flexibility and ease of use are crucial. Their main advantage is their ability to work in close proximity to humans, without the need for massive fences and complex safety systems. In many cases, all that is needed is the right sensor system and operator training for the cobot to perform repetitive packaging operations right next to the workers, supporting the overall process.

Intelligent recognition systems

Solutions equipped with 2D/3D cameras and artificial intelligence algorithms that can accurately recognise both the shape and position of a variety of objects are gaining in popularity. As a result, packaging robots are even better able to adjust the gripping method, even when the products are arranged in unpredictable ways. The ability to automatically adjust the gripping force for fragile objects is also very important.

The most common challenges in implementing packaging robots

Investment costs and justification of ROI

The first barrier is still sometimes the budget. The purchase of a robot, gripping tools and integration into an existing production line represent a major expense. In practice, however, taking into account the savings in labour costs, shop floor space and reduced downtime, the return on investment (ROI) can even take place within 1.5-2 years. To accurately calculate the possible returns, you can use the tools available. If your company is considering automation of processes other than packaging, for example, we recommend testing ROI calculator for welding robotisation. Although it deals with a different task, it gives you an idea of what data is usually needed for ROI calculations.

Lack of sufficient competence within the organisation

Often companies are concerned that staff will not be able to handle advanced systems. However, it is worth remembering that a good integrator (such as Michale Automation) provides not only the delivery of the machine, but also comprehensive training to break down the technical barrier within the team. Moreover, modern operator interfaces are designed to be as intuitive as possible, so that the day-to-day management of the packaging robot does not require expert programming knowledge.

Maintenance and service

To maintain high reliability, regular inspection and maintenance is recommended. Fortunately, many modern robots offer extensive diagnostic systems that signal early on that wear parts need to be replaced. Third-party partner services can also be used. Such support can be invaluable for plants that are unwilling or unable to expand their own technical department.

Who benefits most from packaging robots?

Although automation in packaging is useful in almost every industry, there are industries where the positive effects of this transformation are being felt particularly quickly.

Food and beverage industry

Companies in this sector face high pressure to maintain product freshness and strict hygiene standards. Packaging robots allow products to be packaged safely and hygienically without the risk of contamination. An additional benefit is the stable quality of the packaging, which is important in terms of transport and shelf display.

Cosmetic and pharmaceutical industry

Due to the high level of regulation (e.g. the need to keep track of batch numbers, serialisation of products), the precision of packaging robots is almost invaluable. Thanks to automation, it is also possible to monitor all packaging steps in real time. This makes it possible to ensure transparency in the supply chain and to react quickly to, for example, a possible defective product batch.

E-commerce and logistics

Every year there are more and more customers shopping online, which means there is a much greater need for fast and flexible parcel packing. Robots are able to efficiently separate a variety of products, even in large volumes, improving the efficiency of the entire warehouse and reducing delivery times to the end customer.

Case study: increasing competitiveness in a medium-sized company

It is worth giving a brief example of a company that decided to implement packaging robots and thus gained an advantage in a rapidly changing market.

An example company in the food industry was facing rising labour costs and seasonal fluctuations in demand. Manual packing of products required additional staff during peak periods, which generated significant costs and caused downtime during months with fewer orders. With the implementation of a robotic packing station, the entire process was speeded up while reducing errors (e.g. wrongly sealed packs or incorrectly applied labels). The return on investment was quicker than expected, and the company gained the flexibility to respond to larger contracts without the need for further seasonal recruitment.

Packaging robots in the offer of Michale Automatics

Our company, Michale Automation, supports customers in building complex, state-of-the-art production lines in which robots become a key element of automation. As an official distributor of SIASUN robots, we provide access to advanced machines with different payloads and reach parameters. These solutions are ideal for packaging tasks in the food, cosmetics or logistics industries.

If you would like to learn more about modern packaging robotisation and explore specific solutions, please visit our website Robotisation of packaging.

How do you start preparing for the robotisation of packaging?

Wondering if packaging robots are the right investment for your business? Here's some practical maintenance before embarking on automation:

• Analyse processes and bottlenecks - see where the greatest downtime or errors occur.
• Collect data - how many pieces of product do you pack per week, how many during a period of increased orders, what is the level of waste?
• Determine the budget and realistic expectations of the payback time - can your company invest in a full robotic station straight away, or is a phased implementation of automation needed?
• Compare different technologies and suppliers - a robot with the wrong payload or reach could limit future growth opportunities.

If you have questions about integration and packaging line implementations, also check out Robotisation - main services.

Development perspectives and final conclusions

According to the World Robotics report, the momentum of industrial robotics in Europe is not slowing down, with installation growth reaching 9% in our region in 2023, surpassing the result in North America and Asia. Although the automotive industry remains the main driver here, the packaging sector is also growing strongly. Many companies are looking for efficient and flexible solutions to ensure stable product quality and improve competitiveness. Packaging robots are therefore becoming one of the pillars of the Industry 4.0 strategy, guaranteeing not only lower operating costs, but also the possibility of further scaling up production.

Practical tips - summary

- Identify real needs and define the areas of production that will benefit most from robotic packaging.
- Ensure a detailed analysis of the financial data (labour costs, production volume, surplus or waste) and estimate the possible ROI.
- Work with an experienced integrator (such as the Michale Automation team) who can help match the type of packaging robot to your processes.
- Don't forget training and regular machine maintenance - it's an investment in operational stability and fewer breakdowns.
- Bet on flexibility - the growing role of cobots and intelligent vision systems means that production lines can be adapted to changing market realities.

Completion

Packaging robots are the future for large industrial plants as well as for smaller companies that care about high quality and repeatable processes. If you are thinking about automation, be sure to choose the right machine and supplier. It is worth ensuring a precise needs analysis, openness to changes in the organisation and the perspective of long-term development. All this allows you to implement technology that will not only pay off financially, but also open up the opportunity to introduce new standards in your company. Also check out other areas where robots can improve your production, such as Robotisation of laying.

If you would like to find out more, take a look at our other offers at Michale Automation. Our team will be happy to answer questions and advise you on how to effectively implement packaging robots so that your business can enjoy the benefits of modern automation.

FAQ

What is the robotisation of packaging?
Packaging robotisation is the introduction of specialised equipment and vision systems that automate the process of stacking, sorting and securing products in individual or bulk packaging, relieving workers of repetitive and physically taxing tasks.

Do packaging robots only work well in large plants?
No. As technology develops and more compact solutions become available, smaller and medium-sized companies can also successfully benefit from robotic packaging, adapting solutions to the scale of their production.

How quickly can you expect a return on your investment in packaging robots?
Much depends on the type of process, labour costs and production volume. In practice, companies see a return on investment after about 1.5-2 years, especially if the robotic workstation is running 24/7.

How are packaging robots serviced and maintained?
Regular inspection and maintenance helps to keep equipment running at peak performance. Many modern units have built-in diagnostic systems, and integrators offer maintenance services or remote diagnostics to speed up response to any faults.