How to Choose the Right Packaging Robot for Your Production Line

In the race to optimise operational efficiency and remain competitive in increasingly demanding markets, packaging robots have become a strategic solution in the smart factory ecosystem. For decades, manufacturers have relied on these automated systems for packaging tasks, but today their role goes far beyond simple mechanical repetition: they are now an integral part of connected, flexible and data-driven environments.

This article explores the main processes that packaging robots perform - from primary packaging to palletising and warehousing - and looks at the technical challenges that can arise when integrating them into a production line. In addition, we address the key aspects to consider before investing in these solutions and how their adoption aligns with Industry 4.0 principles, such as real-time traceability, predictive maintenance and full connectivity through cyber-physical systems.

If you are evaluating how to take your production facility to the next level, this analysis will help you understand how packaging robots can be intelligently and cost-effectively integrated into your operations.

Basic processes performed by a packaging robot

Packaging consists of three basic processes: primary packaging, secondary packaging and tertiary packaging.

Primary packaging refers to packaging in direct contact with the product including pick and place applications. For this task a variety of robots can be put in place, for example an articulated robot, a SCARA robot or a Delta robot. The latter might be the best solution, especially if speed is the main concern but if you really want to know the types of robots on the market for these tasks, don't miss the benefits of using collaborative palletising robots to optimise packaging lines.

The next step is the process of removing the products from the containers. Unpacking is done in quick succession, using a different robot and removing the empty containers from the stack. Finally, the depanning robot places the items inside the container. Payload becomes a problem and for this reason, articulated robots that can lift high payloads between 60 and 200 kg must be used for unpacking and destacking.

Secondary packaging includes case packing, which is the process of grouping several individual items into boxes or cases. Collaborative robots are suitable in this respect especially if they are synchronised and capable of handling payloads of up to 20 kg, with some exceptions of more than 50 kg.

Tertiary packaging involves stacking the finished cartons on pallets, which is called palletising. In the case of lightweight boxes, the following can be used collaborative palletising robots to optimise packaging lines. Otherwise, it would be best to opt for a high payload robot. As for the pallets themselves, they could be transported by a mobile robot instead of an employee.

Finally, there is the issue of warehousing. By placing mobile robots in a factory, production is fully automated and therefore time efficiency is improved, speed is increased and the working environment is safer.

Even if all these processes are controlled automatically, employees are still important. An operator who does not understand how a packaging robot works can end up decreasing productivity. Therefore, all end users must be trained to maximise production capacity.

 Things to keep in mind when using a packaging robot

During primary packaging, it may happen that the orientation of each product on the conveyor belt is different. This is solved by placing a camera on the production line which makes an estimation of the position.

Some fragile products cannot be picked up by normal grippers. A solution can be the use of vacuum grippers that adapt to the shape of the object by suction or soft robotic grippers.

Before integrating a packaging robot, the manufacturer must check whether the robot cell as a whole is CE marked. The way to obtain this marking is by following the Machinery Directive, which lists the basic health and safety requirements that a machine operating on the EU market must follow. In addition, a risk assessment must be carried out to identify and reduce potential hazards.

Keeping the machine clean is crucial. Preventive maintenance plans, together with worksheets, are usually provided by OEMs and should be implemented from the outset at regular daily, weekly or monthly intervals. These plans may include replacement of wear parts, machine lubrication, on-site visits, storage of wear parts and operator training.

When it is time to invest in a packaging robot, price need not be the determining factor as the availability of technical support is also important. If the machine parts are of high quality, maintenance costs are likely to be low. It should be known if spare parts are available at short notice, in case something goes wrong, as these factors offset the selling price. Discover the return on your investment in a packaging robot with the collaborative robot ROI vs. cash flow calculation.

The availability of materials at any time is not difficult to obtain under normal circumstances, but in times of high demand, production may stop because of this. Therefore, keeping the supplier informed or buying from several suppliers is a good strategy.

The future of the packaging robot in the age of Industry 4.0

Industrial packaging automation has come a long way since the first robots were used on production lines. What was once a tool to speed up repetitive tasks has now become a key part of smart factories. In a globalised and competitive environment, keeping up to date is not just an advantage: it is a necessity. The future of the packaging robot is inevitably linked to the adoption of emerging technologies such as the Internet of Things (IoT), Artificial Intelligence (AI), Big Data and, especially, cyber-physical systems (CPS).

This article explores how these technologies are transforming packaging robots, from their role in production to their impact on business strategy, customer experience and operational sustainability.

Until recently, robots in packaging tasks were designed to perform specific functions: picking, placing, packing, palletising. Efficiency and accuracy were the main objectives. However, the pressure to adapt quickly to changes in demand, new product formats and traceability requirements has driven a deeper evolution. Today, companies need:

• Flexibility to adapt to multiple product formats.
• Connectivity to integrate robots into industrial networks.
• Real-time visibility of the entire packaging process.
• Cost reduction without sacrificing quality.

And that is where Industry 4.0 comes in.

Industry 4.0: The new ecosystem for the packaging robot

Industry 4.0 represents a radical transformation in the way factories design, produce and deliver products. In this context, packaging robots are not simply autonomous machines: they are intelligent nodes connected within an integrated digital system.

IoT: Sensors that turn data into decisions

Thanks to the Internet of Things (IoT), packaging robots are now equipped with sensors that monitor parameters such as speed, temperature, vibration, position and more. This information makes it possible to detect deviations before they result in defects or downtime. In addition, IoT enables:

• Predict mechanical failures before they occur.
• Adapt production cycles according to demand.
• Integrate the robot with ERP and MES systems.

Artificial Intelligence: Learning Robots

Artificial intelligence allows packaging robots to evolve beyond pre-programmed routines. Through machine learning, robots can identify failure patterns, optimise palletising routes or even adjust gripping force according to the type of product. The benefits are:

• Reduction of material waste.
• Automatic adjustments without human intervention.
• Continuous improvement of online performance.

Big Data: Evidence-based decisions

In each operating cycle, packaging robots generate thousands of data points. Big Data allows them to be analysed in real time and strategic decisions to be made:

• When to carry out maintenance.
• Which configurations generate the highest efficiency.
• Where seconds are lost that could represent millions.

This data can also be fed back into other industrial processes, closing the cycle of continuous improvement.

Cyber-Physical Systems (CPS): The bridge between the physical and the digital

One of the most revolutionary elements in Industry 4.0 are cyber-physical systems (CPS), which integrate hardware (such as robots) with advanced software (such as control, simulation or predictive analytics platforms). In other words, they are systems that not only execute tasks, but also interpret their environment, communicate with other systems and act autonomously.

Full transparency for the customer

One of the most powerful features of the CPS in packaging robots is their ability to offer real-time monitoring of each product. This allows manufacturers to provide their customers with accurate information on:

• The production status of your order.
• Traceability of each batch or unit.
• Compliance with quality standards.

This level of transparency builds trust and can become a powerful industrial marketing tool: customers perceive not only a quality product, but a brand committed to operational excellence.

Challenges to overcome along the way

Although the future is promising, the integration of advanced packaging robots in an Industry 4.0 environment presents certain challenges:

• Initial investment costWhile the ROI can be high, the barrier to entry requires careful planning.
• Staff trainingOperators need to understand how to interact with intelligent robots.
• Interoperabilitynot all existing systems are ready to connect to a cyber-physical environment.
• Information securitygreater connectivity also means greater exposure to digital threats.

The key is to have technological partners that offer not only the robot, but also support in integration, training, maintenance and scalability.

Conclusion: Adapt or be left behind

The future of the packaging robot for the end-of-line automation is not just about improving speed or reducing errors: it is about being part of an intelligent, autonomous production network that can respond in real time to market needs, changes in demand and the highest quality standards.

Companies that adopt these solutions will be better positioned to compete globally, reduce operational costs and deliver a more transparent and reliable customer experience.

The question is no longer if to integrate advanced technology into your packaging lines, but rather to when y with what strategy you are going to do it.