43 www.drivesncontrols.com January 2026 PACKAGING AND PRINTING n How automation is transforming packaging Packaging is emerging as one of the most urgent frontiers for automation. Once seen as the final step of production, it now demands alignment of speed, labour, material-handling and error reduction, while addressing evolving operational challenges. Packaging lines endure some of the highest unplanned downtime, due to the high amount of repetitive labour involved. These risks are compounded by tightening sustainability requirements, rising safety standards, and an acute shortage of skilled personnel. In response to these challenges, manufacturers are turning to automation. According to Martynas Česnaitis, head of automation at the Lithuanian robotics company VMG Technics, one of the most visible shifts is the move from plastics to recyclable, paperbased packaging.“This is motivated by tightening regulatory requirements and customer expectations,”he says. “Packaging automation systems are being redesigned to accommodate these new materials, often more fragile or variable than plastic packaging." Another shift is the introduction of autonomous logistics. Mobile systems such as AMRs (autonomous mobile robots) and AGVs (automated guided vehicles), are taking over the movement of materials between production and packaging zones. This reduces manual material handling, and increases safety and efficiency. AI is also set to play a defining role in the packaging sector. AI vision systems and predictive analytics are helping manufacturers to detect defects in real time, anticipate maintenance needs, and improve processes. “We are moving quickly towards smart packaging lines that encompass AI vision systems, data analytics, and robotics into one self-monitoring process,”says Česnaitis. “This means we can identify issues in real time, perceive faults before they happen, and continuously improve processes with constant performance data." He emphasises that the future of packaging automation isn’t about replacing labour, but building adaptable, scalable systems, and creating high added-value jobs. AI, robotics and predictive tools enable faster, smarter packaging, while reducing downtime and waste. They can transform the workforce, with companies investing in retraining workers to operate, maintain and analyse data from advanced systems. These broader trends are especially relevant in industries such as manufacturing wood products, where packaging presents unique challenges. The products can vary significantly in size and shape, and lines must sustain high output while ensuring each part is packed securely, safely and consistently. As customer demands grow more diverse and product lines become more sophisticated, the need for highoutput, low-error packaging is increasing. Take, for example, Klaipėdos mediena, one of the largest furniture manufacturers in the Baltics, which produces kitchen cabinets and 1,800,000m2 of melamine-faced particle boards every month. It has recently overhauled its packaging operations. In response to recurring bottlenecks and labour constraints, it introduced machine vision inspection, robotic forming and sealing systems, and automated cells for defect handling. Česnaitis explains that the automation was not a shortcut, but a structural upgrade. “Packaging is often treated as the last step, but it became the focal point,”he reports.“In wood processing, the packaging stage must handle large, variable components precisely. Any failure here affects logistics, customer satisfaction, and ultimately competitiveness and profitability. Automation gave us the consistency we needed to meet demand reliably.” Following the four-year overhaul,the company’s productivity rose by 33%, from 16.3 to 21.76m2/h, and its work rate increased from 9 to 12 parts per minute. Robots now handle components up to 2.4m wide, improving workplace safety and reducing strain. Automated inspection has also enhanced quality by reducing human error and variability. “The biggest challenge was not the technology itself, but rather integrating technology into a live, high-volume production environment,” recalls VMG Wood Invest CEO, Ingrida Grikpėdienė. “Each solution had to be aligned with real production workflows, calibrated among many production lines. It was not just about installing machines, it was about optimising operations through an innovative technological approach to secure long-term sustainable business, and ensure high addedvalue jobs as well as ergonomic working.” n As manufacturing faces growing pressure from labour shortages, sustainability, and quality demands, packaging is becoming critical, especially in high-volume sectors. One of the Baltic’s largest furnituremakers has restructured its packaging operations, revealing broader shifts in the sector. Robotics and automation are transforming packaging operations Image: VMG Technics
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