For consumer packaged goods (CPG) manufacturers maintaining productivity protects profits. However, achieving productivity goals requires continuous optimization of lines to increase efficiency, conserve resources, reduce waste, and cut costs. 

Optimizing often depends on automation. As a result, more automated systems are being installed, particularly for product and package handling, palletizing and pallet handling, horizontal forming/filling/sealing, and packaging inspection, the top four machinery categories noted in the 2024 State of the Industry report published by PMMI, The Association for Packaging and Processing Technologies.

Automated systems frequently involve robots or cobots (collaborative robots), which offer the flexibility to handle the wider range of product and packaging formats demanded by retailers and consumers. While automated systems remain popular tools for optimization, CPG companies also are adopting advanced technologies such as digital connectivity, data collection functionality, AI, augmented reality, virtual reality, and advanced human/machine interfaces. These technologies can not only help optimize operations but also overcome labor shortages and positively impact employee retention.

Collecting real-time data offers many benefits, according to another report from PMMI, Data Acquisition, Sharing and Utilization by providing better visibility into current performance, delivering downtime metrics, and reducing manual errors When used to monitor the operation and condition of machines, this information can provide an early warning of failure, support predictive maintenance programs, and enhance operational efficiency.

Unfortunately, there are barriers to implementation including cost, the need to standardize data protocols, difficulties in transitioning from manual to automated data capture, challenges associated with data aggregation, and lack of skilled data technicians and financial and IT resources. For maximum value, all stakeholders must understand the significance of the data they are receiving and recording. 

To streamline implementation, the report suggests starting with overall equipment effectiveness (OEE) and three machine parameters — status, speed, and output. Other guidance for OEE includes three work products from PMMI’s OpX Leadership Network, OEE Guidelines, OEE Benefits Calculator, and OEE Starter Tool.

The Data Acquisition, Sharing and Utilization report also recommends:

• Fostering a data-first culture
• Gradual implementation of data collection and utilization
• Standardizing on a common protocol for digital connectivity
• Upgrading legacy equipment with sensors and programmable logic controllers.

It concludes, “By standardizing and scaling data processes, companies can enhance efficiency and reduce machine downtime. Success lies not only in deploying advanced technologies but also in creating a culture throughout the company that values data as a strategic asset and understands how it is being captured and utilized.”

As more attention focuses on data utilization, interest is growing in AI, which can analyze vast amounts of historical and real-time information to detect subtle patterns that human operators might overlook. Thus, AI can support the automation of complex tasks, streamline processes, minimize downtime, enhance quality, and cut costs. AI also can help achieve sustainability goals by optimizing production processes, reducing waste, and improving resource management. However, its biggest benefit may be its ability to continuously learn from the data it collects. As a result, AI-powered systems become more accurate over time, thereby enabling better, data-driven decisions.

In the short term, the greatest impact of AI is expected to be on predictive maintenance, according to another PMMI report, 2024 Transforming Packaging and Processing Operations. This downtime-reducing tool relies on data gleaned from sensors to forecast asset behavior, enabling repairs to be performed proactively, while also minimizing product loss, extending machine life, and minimizing spare parts requirements, according to the Packaging and Predictive Maintenance report, also published by PMMI.

Other efficiency-boosting applications such as yield and supply chain optimization and production planning/scheduling also can benefit from AI, according to the Transforming … Operations report. For yield and supply chain optimization, AI algorithms can analyze sales, inventory, and market trend data. By predicting demand patterns, AI systems can help streamline inventory management, reduce waste, and ensure optimal stock levels.

For labor allocation and machine utilization, instead of relying on historical trends, equipment knowledge, and estimates of product demand, AI can analyze real-time manufacturing data, sales, supplier status, equipment efficiency, and other factors to create optimized schedules, which eliminate bottlenecks.

Reaping the benefits of AI is not without challenges. One obstacle is the collection and analysis of the massive volume of data generated by sensors and machines. This requires robust data infrastructure and analytics capabilities to ensure accurate predictions and streamlined operation. Implementing AI also requires skilled personnel, so upskilling existing workers or hiring personnel with AI experience is critical to fully harness its potential.

CPG manufacturers striving to achieve productivity goals have a new resource, the inaugural PACK EXPO Southeast, March 10–12, 2025, at the Georgia World Congress Center in Atlanta, a regional manufacturing hub and easily accessible destination. With 500+ exhibitors spread over 110,000 net square feet, attendees can explore new technologies, observe equipment in action, compare machines, meet key partners, and find new packaging materials.

Packed with opportunities for innovation, education, and connection, the debut event offers sustainable solutions such as mono-material design and reusable options, expert-led sessions on industry trends, and presentation of cutting-edge technologies such as automation, robots and cobots, AI, augmented reality, virtual reality, and predictive maintenance, as well as innovations for anticounterfeiting, smart packaging, e-commerce, food safety, and cold-chain packaging.

Discover the future of packaging and processing at the new PACK EXPO Southeast, the most comprehensive show in the region offering crossover solutions for today’s biggest packaging and processing challenges. For more information and to register online, visit packexposoutheast.com.