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Automate - Unleash the potential in your processes

Automating production processes while reducing costs, increasing quality and securing competitive advantages – this is what the right automation strategy can achieve.

How much potential is there in your production processes? The global market for industrial automation is growing rapidly: from 206 billion US dollars in 2024, it is expected to grow to 379 billion US dollars by 2030 [1]. Companies that rely on smart automation reduce their operating costs by a fifth on average. For Sleeve applicators, taping machines and Custom solutions, this means that those who automate now will secure decisive competitive advantages for the future.

Why automation is becoming a game changer in the Packagings sector

The figures speak for themselves: 60% of companies worldwide already use digital automation solutions [1]. They are increasing their efficiency, improving product quality and reducing the workload of their employees. Automated systems offer enormous benefits, particularly in the packaging sector:

  • Reduction in material and personnel costs
  • Increase in process speed
  • Consistently high quality even with large quantities
  • Flexible adaptation to different product formats

The degree of automation in production facilities will increase from the current level of around 70% to almost 80% within the next ten years [2]. This development shows that Automation is not a short-term trend, but a strategic necessity for sustainable companies.

Automation in the Packagings sector: these technologies are shaping the market

Modern packaging automation combines mechanical components with Sensor technologies, intelligent software and process control tools. This results in systems that work precisely, quickly and reliably. Our most important fields of technology at a glance:

Sleeve applicators: Flexible Labeling with added value

Sleeve labeling machines apply shrink labels fully automatically to a wide variety of container shapes – from round to asymmetrical products. The advantages:

  • 360-degree branding with full-surface decoration
  • High labeling speed with minimal personnel deployment
  • Tamper-proof seal for tamper protection
  • Modular expandability for different production requirements

The technology adapts perfectly to your products using specialized shrink tunnels or steam tunnels and achieves a uniform shrink result even with complex packaging shapes – thanks to control via digital information on temperature, speed and product geometry.

Adhesive tape machines: Efficiency in the sealing process

What do modern taping machines do? They automate the sealing of Packagings and thus significantly increase the process speed. Modern systems process different product shapes and carton sizes without manual intervention and automatically adjust the tape length.

The integration of Sensor technologies for product recognition and programmable work cycles make these machines a key element in automated Packaging lines. Particularly valuable: the reduction in personnel costs and simultaneous increase in packaging quality.

Shrinking (process) tunnel: Precisely fitting product wrapping

Shrink tunnels are a central element in modern packaging processes. They enable:

  • Precise Shrinking (process) of Sleeves and Films / Foils
  • Adaptation to different product geometries
  • Energy-efficient work thanks to optimized heating systems
  • High throughput with consistent quality

Modern Shrink systems have intelligent control systems that automatically regulate the temperature and throughput speed to ensure optimum results.

Special machine construction: Customized automation solutions

Custom machinery construction comes into play when standard solutions reach their limits. It develops customized automation solutions for specific requirements.

Advantages of special machine constructionFeatures
Individual customizationMachines are designed exactly for your production requirements
Seamless integrationOptimum integration into existing production lines
Increased efficiencyTailor-made process optimization for maximum productivity
Future-proofFlexible adaptability to changing requirements
Custom machinery construction covers the entire value chain from engineering and design to commissioning and maintenance. It closes gaps in automation processes and creates end-to-end production processes [3].

Key trends in packaging automation

The automation of packaging processes is constantly evolving. Five key trends are currently having a particularly strong impact on the industry [4]:

  1. Artificial intelligence: AI systems are increasingly taking on control and optimization tasks. They analyze production data, recognize patterns and automatically adjust process parameters.
  2. Collaborative robotics: Cobots work safely with humans and perform flexible Packagings and handling tasks.
  3. Sustainability: Energy-efficient drive systems, resource-saving processes and optimized material consumption are the focus of modern automation solutions.
  4. Flexibility: Fast format changeovers and adaptable systems allow different products to be processed efficiently on one line.
  5. Networking: Machines communicate with each other and with higher-level systems, exchange digital information and thus enable end-to-end transparency and control.

Automation: more than just technology

What makes automation projects successful? Technology alone does not guarantee success.

  • A clear strategy with defined goals
  • Employees who support and understand change
  • An experienced technology partner with industry expertise
  • Gradual implementation instead of radical upheaval
  • Digital tools for transparent process monitoring and data evaluation
  • Continuous optimization after implementation

Particularly important: the involvement of everyone involved right from the start. Automation only works if it is supported by the people who work with the systems.

Practical examples: Automation in the Packagings sector

1.

Sleeves Labeling in the Beverage Industry

A Spanish dairy group expanded its existing aseptic plant to include an automated Sleeves Labeling machine [5]. The integration enabled:

  • Fully automatic Labeling in the aseptic process
  • Greater flexibility for product changes
  • Increase in the overall output of the line
  • Reduction of rejects through precise Labelings
2.

Automated Packagings for e-commerce giants

Amazon is increasingly relying on automated packaging technologies in Europe [6]. The systems:

  • automatically adapt carton sizes to products
  • reduce packaging material and transport volume
  • speed up the entire packaging process
  • improve customer satisfaction through optimized Packagings
3.

Special machine solutions in the food industry

A leading food manufacturer needed a solution for the automated bundling of different product formats. The Custom solution developed:

  • Flexibly processes different product sizes
  • integrates seamlessly into the existing production line
  • Reduces personnel costs by more than 40
  • Increases throughput by 35

Automation and jobs: A differentiated view

Automation is changing the world of work – but not necessarily for the worse. By 2030, around 90 million jobs will be lost worldwide due to automation. At the same time, however, 170 million new jobs will be created, resulting in a net increase of 78 million jobs [1].

However, the new jobs require different qualifications. Companies should therefore:

  • invest in the qualifications of their employees at an early stage
  • Develop new job profiles at the interface between man and machine
  • Actively shaping change instead of just reacting

Automation does not mean the end of human work, but rather its transformation. Technology is taking over repetitive tasks, while creative and strategic activities are gaining in importance.

The right partner for your automation projects

When choosing a technology partner for your automation projects, you should pay attention to the following factors:

  • Experience and industry knowledge
    Look for a partner who knows your industry and its specific requirements. Experience with similar projects is worth its weight in gold.
  • Holistic approach
    Automation only works if it fits into your overall strategy. A good partner thinks in terms of solutions, not just machines.
  • Future-proof
    Look for modular, expandable systems that can grow with your company and adapt to future requirements.
  • Service and support
    The best automation solution is of little use without reliable service and support. Therefore, check the availability of spare parts, maintenance offers and emergency services.

Conclusion

Automation as a strategic success factor

The automation of process sequences offers enormous potential for increasing efficiency, improving quality and reducing costs. Especially in the areas of sleeving machines, taping machines, Shrink tunnels and Custom machinery construction, there are great opportunities for companies that want to strengthen their competitiveness.

However, it is not just the technology that is decisive for success, but also the strategic approach. Automation must fit the company, its processes and its people. With the right partner at your side, digital automation becomes a sustainable competitive advantage.

Berning's top 5 arguments for process automation

  1. Increased performance and quality
    Automation ensures constant, precise implementation of processes and thus reliably increases product quality and production output.
  2. Protecting employees through better ergonomics
    Repetitive and stressful manual tasks are reduced, improving working conditions and reducing physical strain.
  3. Reduction in error rates
    Automated processes minimize human error and ensure greater accuracy and reliability in production
  4. Streamlining processes
    Automation leads to leaner, more efficient processes that save time and make optimum use of resources.
  5. Future-proof and competitive
    Berning uses innovative automation technologies to ensure that it remains at the forefront of the market in the long term and is able to react flexibly to new requirements.

Would you like to find out more about the possibilities of automation in your company? Berning Maschinenfabrik supports you with tailor-made solutions – from individual components to complete automation of your packaging processes. Contact us for an individual consultation and tap into the potential of automation for your company.

Customized automation solutions?
You've come to the right place!

Florian Ochse
Consultation with Florian Ochse

Sources

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