Automation in Print & Packaging: How to Streamline Production and Cut Cost?

Automation in print & packaging is trending nowadays and use by brands to streamline production and cut costs to a greater extent. It works when customer asks for faster turnarounds, smaller runs, higher complexity, and lower prices.

In this blog post, we outline how automation works & what it delivers? Additionally, how would you save a lot with this process? We also share real-world savings and stats, and a practical roadmap, that works very well, especially for small businesses.

Why Automation in Print & Packaging Matters?

The global market of packaging & print automation processes is expanding steadily, showing how brands are investing on it to reduce costs. Industry estimates put the market at roughly $72–78 billion in 2024.

Beyond market size, automation produces measurable operational improvements and cut down operational expenses up to 30%. This type of change almost every business demand, and also become a necessity.

Practical Roadmap to Streamline Production & Cut Cost

1. Start with a Process Audit

From file submission to palletizing, outline the full job flow. Measure these things:

• Cycle times
• Scrap %
• Changeover durations
• Labor touchpoints

Do complete bottleneck analysis because automation process delivers the best ROI if bottleneck analysis is done with proper concentration.

2. Automate Prepress and Workflow

Automated prepress workflow and web-to-print porta eliminate manual file fixes and reduce overall time or cost. Also, it reduces human touch and turnaround time to make things even better.

3. Move to Digital/inline Finishing for Flexibility

Inline finishing means cutting, folding and laminations. When you combine both digital presses and inline finishing, printing and finishing steps are conveniently combined in a single flow that ultimately reduces the cost of manual changeover.

4. Install Targeted Robotics at End-of-line

Robotic case erectors cut costs and manual handling/ packaging cycle time. The automation during end-of-line process improves ergonomics and reduces workplace injuries. So, in short, automation consistently provides efficiency and flexibility.

5. Integrate Systems: MES, ERP, and IoT

Real-time scheduling and inventory control is must to streamline whole production process. MES & ERP are ideal for scheduling and inventory control. On the other hand, IoT is designed for predictive maintenance which lowers maintenance costs.

6. Use Predictive Maintenance and Digital Twins

Condition monitoring avoids catastrophic failures. McKinsey-level case studies show automation plus data analytics can lift productivity dramatically. In one example, productivity in processing rose more than 70%, and filling/packaging improved by nearly 280% after integrated automation.

7. Train and Redeploy Staff

Shifting from manual processes to automations will not be enough for your brand, train your staff as well to execute perfect results. It reallocates human force to supervision, quality control, programming, and continuous improvement. Must invest in it.

8. Measure ROI and Use Pilots

In last, do not forget to measure ROI and use pilots. Track KPIs: throughput, OEE, scrap rate, labor-hours per shift, and lead time. Typical goals: recover capex within 12–36 months depending on automation scope; aim for incremental OEE improvements.

What to Think About Before You Invest?

• Do you know your recent cost per unit?
• Think which line is your bottleneck?
• Can a pilot reduce cycle time?
• Is integration of any thing feasible with your business?
• Do you have any future plans for your staff?

After getting answers to these questions, invest wisely.

In a Nutshell!

Automation in print and packaging has become a necessity of time. Without this, it is quite difficult for brands to cut down operational and production costs. When planned and executed correctly, automation works well.

Additionally, manual workflows are decreasing with time and brands opt automative techniques or procedures to make work done in less time. So, incorporate automation into your product printing and packaging to improve efficiency and save costs. For more packaging related tips & ideas, stay in touch with Kolaxo Print.