Balancing Sustainability and Efficiency in Packaging Processes | Rockwell Automation

The growing emphasis on sustainability and its importance in the packaging sector is continually growing year on year. Packaging processes and product development now need to be as sustainable as possible to meet consumer demand, while still standing up to the required sealing requirements and barrier properties.

As a result, packaging companies are now increasingly committing to more ambitious sustainability targets. These are set by the companies themselves as well as governmental regulations such as the recent Paris agreement, which are making the implementation of sustainable packaging solutions a top priority

However, numerous challenges still exist beyond just emphasizing sustainability for packaging companies. This demand needs to be balanced alongside ongoing cost pressures, consumer perceptions, and the need for efficient and optimized production. These challenges faced by packaging companies looking to implement more sustainable packaging solutions can be successfully addressed using innovative technological solutions and successful partnerships to give modern consumers everything they want from their packaging.

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Balancing Sustainability and Cost Pressures

With the rising demand for sustainable packaging, companies face the challenge of meeting environmental goals while keeping overall operational costs in check. It can quickly become a redundant expedition to make more sustainable packaging only for the costs of producing it to skyrocket and be pushed onto the consumer. Therefore, for packaging companies it becomes important to first understand this dilemma and look to focus on enabling super-efficient production processes.

By prioritizing innovative operational practices without increasing cost – something which automation and digital transformation can help to enable successfully – packaging companies can empower consumers to adopt sustainable packaging solutions without compromising their financial objectives. After all, people are demanding more sustainable practices, but there is a cap on how much they are willing to pay for this before it outweighs their convictions. Embracing a digital transformation approach that utilizes automated processes ensures that packaging companies can make meaningful progress toward sustainability while maintaining their competitiveness in a cost-conscious market.

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Consumer Perceptions Shaping Material Choices

Consumer perceptions play a crucial role in the development of new packaging solutions. Many consumers may struggle to differentiate between complex and difficult-to-recycle plastics and mono plastics, which are considered more sustainable. Ironically, paper packaging enjoys a more positive perception compared to plastics, even if it is not always more sustainable than the plastic alternative.

To address this, companies have directed their research and development efforts toward paper solutions and ensuring consumers are well-informed of the sustainability angle, through clear designs and labelling. By exploring new materials and manufacturing processes, such as wet pulp molding and dry forming, to introduce innovative paper-based products into the market, companies can target this increased demand. This gives the consumer what they want without sacrificing product quality or efficacy, something especially important for products in the food and beverage sector.

This shift aligns with consumer preferences for sustainable materials and demonstrates the companies' commitment to meeting evolving market demands, highlighting the need for companies to adopt this approach, and adopt it quickly.

Emerging Technologies: AI, Digitalization, and Automation

As sustainability gains greater prominence with the growing demographic of younger consumers, emerging technologies like AI, digitalization, and automation play a crucial role in driving the development of more sustainable packaging processes and materials.

AI is utilized to enhance the usability of packaging lines, providing operators with real-time guidance and insights. By leveraging AI capabilities, machines can proactively assist operators in resolving issues and optimizing processes, resulting in reduced downtime and improved efficiency for more sustainable products that can provide problems of their own when running on existing packaging lines.

Alongside AI, digitalization and automation can enable better control over packaging processes, leading to reduced energy consumption and improved resource efficiency. By analyzing data and implementing smart control systems, customers can identify areas for optimization and achieve substantial energy savings, making their own operations more sustainable in the process. This energy reduction - potentially up to 20-30% in some cases - underscores the impact of these technologies in driving sustainability within the packaging industry, not just in terms of final products but overall operations.

Implementing sustainable packaging solutions poses significant challenges for companies striving to balance environmental goals, cost pressures, and customer expectations. But companies should look to address these challenges head-on through their commitment to efficient production and setting aggressive sustainability goals.

To achieve this, packaging companies would benefit from working in partnership with companies who have a deep understanding of the industry and can support with reaching these goals through situations where the sum of all parts add up to more than the whole. By working together, packaging companies can become more sustainable, without impacting their efficiency goals or profit margins.

To learn more about balancing sustainability and efficiency in packaging processes, watch the ROKStudios interview with Dr Stefan König.

Published October 11, 2023

Dr Stefan König

Managing Director, Optima Packaging Group

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