Packaging Challenges, Trends & Best Practices for Improved Operations

Every product that reaches a customer goes through packaging operations. This makes the packaging industry central to modern commerce. Facilities therefore have a major responsibility to protect products, support supply chains and drive profitability across sectors. As a result, there is mounting pressure on packaging operations to be as efficient as possible. 

Labour shortages, unpredictable demand, more stock-keeping units (SKUs), faster changeovers and tighter safety regulations are reshaping how facilities operate. Material handling has become a critical bottleneck. 

Plants that are solving these material handling challenges usually benefit from increased speed and reduced injuries, helping them to remain competitive. Those failing to adapt face downtime, waste and rising costs. 

Table of Contents 

• What Material Handling Means in Packaging Operations 
• Why Material Handling Is Critical for Packaging Success 
• Key Packaging and Material Handling Challenges 
• Packaging Automation & Other Important Trends 
• Safety and Ergonomics as Competitive Advantages 
• Best Practices for Smarter Material Handling & Packaging Equipment 
• Moving Forward with Smarter Material Handling 

What Material Handling Means in Packaging Operations

Material handling in packaging refers to the movement, storage, and control of raw materials and finished products throughout production. This includes lifting rolls of film or paper, moving cartons between stations, positioning sheets for feeding into machines and stacking finished packages for distribution. 

Packaging operations handle items repeatedly. Someone might lift a roll of film from a pallet, transport it to a machine, mount it for unwinding, and then replace it when empty. Workers fill, seal, label, inspect, and palletise boxes within the same shift. Each touchpoint creates an opportunity for injury, damage or delay. 

The materials vary widely. Packaging plants handle films that can come in different shapes and sizes, heavy corrugated rolls weighing 80 kg or more, fragile glass containers and unstable stacks of folded cartons. This requires different lifting techniques, so each material is lifted and moved efficiently and safely.  

This complexity explains why material handling sits at the centre of production speed, product quality and worker safety. 

Why Material Handling Is Critical for Packaging Success 

Three factors make material handling essential: speed, safety and consistency. 

Speed and Throughput

Packaging lines run fast. A bottling line might fill 600 units per minute. A carton erector could handle 40 cases in the same time. Waiting for a roll change, struggling with heavy loads, or repositioning pallets stops the line. A two-minute holdup repeated across shifts costs hundreds of units in lost output. 

Efficient material handling, such as utilizing packaging automation systems, keeps machines fed and lines moving. Quick mounting of rolls, easy switching between materials and rapid movement of finished goods maintain the rhythm that high-speed packaging demands. 

Safety and Injury Prevention

 Manual handling causes most packaging facility injuries. Lifting heavy rolls strains backs and shoulders. Twisting while carrying loads damages knees. Repetitive movements lead to cumulative trauma.  

The European Agency for Safety and Health at Work notes that manual handling of loads exceeding 25 kg typically violates ergonomic safety guidelines. Many packaging materials weigh far more. 

Lost work time, increased insurance costs, damaged team morale and compliance risks are often a consequence of injuries. Plants investing in safer handling methods can protect their workforce and their profitability. 

Quality and Consistency 

Damaged materials create quality problems. A dented roll edge causes feeding issues. Crushed cartons get rejected. Contaminated film ruins entire batches. Operators struggling with awkward loads make more mistakes. 

Proper handling equipment reduces material damage and maintains quality standards throughout production. Regulated industries like pharmaceuticals and food see particular benefits, where minor defects can trigger costly waste. 

Key Packaging and Materials Handling Challenges 

There are multiple packaging industry challenges which facilities need to be aware of when it comes to enhancing operations. Challenges include the labour shortage, SKU proliferation, machine uptime and more. 

Labour Shortages and Workforce Strain

 The packaging sector struggles to find workers. In fact, 95% of packaging end users face difficulties recruiting skilled operators and technicians [PMMI's 2025 Inside the Workforce Gap report]. This shortage affects machine operation, material handling and quality control. 

The problem extends beyond numbers. Existing staff work longer hours, handle more responsibilities and therefore face greater physical demands. Under increased fatigue, the likelihood of mistakes being made grows, potentially leading to injuries.  

This makes physical tasks more problematic. A facility that once had three people to handle heavy rolls now has two. Jobs requiring staff rotation to prevent strain now fall on the same individual shift after shift. 

Addressing the Labour Shortage 

Packaging automation systems can help address labour shortages and improve operational efficiency. Semi-automated solutions like smart lifting enhance productivity without rendering human roles obsolete. Full automation, on the other hand, risks displacing skilled workers without leveraging their expertise and fully robotic systems often ignore the adaptability of experienced workers. In short, smart lifting empowers a broader workforce, including those with mobility restrictions or older employees who may no longer be in their physical prime. 

By reducing the strain of heavy or repetitive tasks, semi-automated packaging equipment minimise wear and tear on the body, preventing both immediate injuries and long-term occupational damage, and also create a more inclusive and flexible work environment. This approach preserves the value of existing skills while extending careers, attracting diverse talent, and maintaining morale instead of eliminating jobs outright. 

Smart lifting tools include: 

• Vacuum lifters: Use suction power to lift heavy loads effortlessly.
• Hoists and cranes: Mechanically move large or awkward items.
• Trolley systems and conveyors: Reduce manual handling distances. 

SKU Proliferation and Shorter Production Runs 

Customers want variety. A brand that once offered five flavours now sells twelve, each with multiple package sizes and seasonal variations. This stock-keeping unit (SKU) proliferation drives complexity throughout packaging operations. 

More SKUs mean shorter production runs. A line might switch between four products in a single shift instead of running one product for eight hours. Each changeover requires different materials such as new rolls, different carton sizes or alternative labels. As a result, operators spend more time setting up and less time producing. 

Material handling also becomes more demanding. Workers move diverse items more frequently while dealing with varying weights and dimensions, and requiring greater flexibility. Ultimately, the physical toll compounds as variety increases. 

Demand Volatility and Capacity Planning 

Packaging demand fluctuates unpredictably. For example, e-commerce surges during holidays, then drops off at other times of the year. Seasonal changes also affect packaging, because the weather must be considered in terms of damage to packaging, as well as supply chain disruptions. As a result, capacity planning becomes difficult and operations designed for steady throughput can become strained. 

Furthermore, volume spikes intensify material handling bottlenecks. When more materials move through facilities faster, there is the potential for storage areas overflow while operators rush to keep pace – causing an increased risk of injury to workers. 

Facilities that are able to smoothly handle peak demands typically have flexible material handling systems that scale with volume.

Packaging Equipment Uptime and Changeover Speed 

Ergonomic packaging equipment represents significant capital investment, so maximising uptime matters. However, many facilities lose productive hours to preventable delays such as: 

• Waiting for material delivery
• Struggling with roll mounting
• Clearing jammed feeds
• Dealing with damaged supplies

Changeovers also present particular challenges. Plants reducing changeover time from 30 minutes to 15 minutes gain substantial capacity. Much of that speed improvement comes from better material handling. 

Material Diversity and Sustainability Pressure 

As packaging materials continue evolving, so too can the challenge of handling newer materials. As brands shift towards recyclable films, paper-based alternatives, and/or lightweight substrates, handlers must meet the demands of the packaging’s delicateness. For example, newer materials may require different tension control or need modified processing. 

Lightweighting, often for sustainability reasons, reduces material usage but creates thinner, more fragile products that need careful handling. As a result, operators must further adapt their techniques as materials change.

Packaging Automation & Other Important Trends

 Several trends are reshaping how packaging facilities operate. Understanding these shifts helps plants prepare for changes ahead. 

Packaging Automation Systems for Workflow Efficiency

 Packaging automation is expected to play a key role in the future of the packaging industry. The packaging automation market is forecast to grow to $134.6 billion by 2032, up from $78 billion in 2025 [Fortune Business Insights]. This reflects widespread adoption of automated filling, sealing, labelling and palletising systems. 

Often, facilities start with semi-automated solutions such as assisted lifting packaging equipment like TAWI’s vacuum lifters. These partial automation steps reduce physical strain, improve speed and prepare operations for future expansion. 

Choosing a packaging automation system that fits current needs while allowing growth is the key consideration.

Flexible Production Systems 

Packaging lines must handle variety. Flexible packaging equipment adjusts quickly between product sizes, package formats and material types. This flexibility becomes essential as SKU counts rise and production runs shorten. 

Material handling plays a central role in flexibility. Equipment that can adapt to different roll diameters, switching between carton sizes, or adjusting lifting capacity without lengthy setup means faster changeovers. Plants can invest in versatile handling tools serving multiple product lines instead of having dedicated equipment for each SKU. 

Workforce Adaptability and Cross-Training 

With fewer workers available due to the labour shortage, facilities need increasingly adaptable teams. Cross-training allows staff to cover multiple roles, fill gaps when colleagues are absent and support different production lines as volume shifts. 

Ergonomic material handling equipment supports cross-training. Packaging equipment that is intuitive and reduces physical demands allows more workers to handle materials safely, regardless of their size or strength. This flexibility helps facilities maintain production when specific operators are unavailable. 

Safety and Ergonomics as Competitive Advantages 

Safety is crucial in terms of preventing accidents and being compliant. Safety is also a business advantage. Facilities with strong safety records attract better workers. They also reduce insurance costs, maintain productivity and build reputations as responsible employers. 

The Business Case for Ergonomic Packaging Equipment 

Ergonomic packaging equipment for material handling prevents injuries. Workers using assisted lifting stay productive longer. They also make fewer mistakes, take less sick leave and maintain better morale. More efficient material handling also delivers greater business benefits, as well as increased worker happiness and safety. 

Additionally, the case for ergonomic packaging equipment becomes clear given that workplace injury costs extend beyond direct medical expenses. Lost productivity, replacement worker training, increased insurance premiums and potential regulatory penalties add up. Preventing injuries through better equipment typically costs less than managing their consequences. 

Reducing Physical Strain Across Shifts 

Physical work takes a toll across a shift. An operator might feel fine lifting 30 kg rolls for the first hour. By the middle of the shift, fatigue may set in. A Semi-automation systems have lower investment costs c s a result, the likelihood of mistakes being made increases, particularly as worker movements can get sloppy. 

Is unassisted packaging and materials handling really worth the risk? 

Assisted material handling maintains consistent performance throughout shifts. Ergonomic packaging equipment handles the weight while operators control positioning and timing. Cumulative strain reduces and workers remain effective throughout the day. 

Meeting Regulatory Requirement 

Safety regulations continue tightening. Employers must assess manual handling risks, implement control measures and demonstrate duty of care. Facilities proactively addressing ergonomics stay ahead of compliance requirements and avoid costly violations. 

Documentation also matters. Plants need records showing they have addressed known risks, trained workers properly and provided appropriate equipment. This protects against liability claims and demonstrates responsible management. 

Best Practices for Smarter Material Handling & Packaging Equipment 

Improving material handling does not require complete overhauls. Focused changes in key areas deliver measurable results. 

Assess Your Current Handling Challenges 

It’s crucial to understand current matieral handling challenges. Start by understanding where problems exist, so you could walk the floor and observe material movements or ask operators which tasks cause the most difficulty. 

Other assessment tips include: 

• Review injury records to identify recurring issues 
• Check production logs for delays related to material handling 

Common trouble spots include roll changeovers, carton palletising, heavy item positioning and material transfer between stations. Focus improvements on these high-impact areas first. 

Match Ergonomic Packaging Equipment to Materials and Tasks 

Different materials need different handling approaches. For example, rolls of film or paper benefit from lifting trolleys that can mount them directly onto machine shafts. Boxes and cartons particularly work well with vacuum lifters gripping multiple items. Sheets need panel lifting equipment with large contact surfaces. 

Choose ergonomic packaging equipment based on actual workflow requirements. Consider material weights, dimensions, handling frequency and available space. Solutions fitting naturally into existing processes get used consistently. 

For more information, explore our smart reel handling equipment. 

Prioritise Versatility and Adaptability 

Equipment handling multiple tasks provides better value than single-purpose tools. Vacuum lifters with interchangeable suction feet can switch between boxes, bags and sheets.  

Mobile vacuum lifters, meanwhile, provide the freedom to lift and move goods anywhere. It is valuable when you need ergonomic handling in multiple locations or where no permanent installation is possible. In general, they are highly versatile lifters. 

Versatility matters especially for facilities with diverse product portfolios or changing material mixes. Having adaptable packaging equipment accommodates growth without requiring constant replacement. 

Design Workflows for Efficient Movement 

Layout affects handling efficiency. Materials should flow logically through receiving, production, and shipping. 

Workflows should be designed with our below recommendations: 

• Minimised travel distance 
• Minimal direction changes 
• No unnecessary transfers 
• Materials positioned close to where they are needed 
• Rolls stored near machines using them 
• Carton stocks placed adjacent to packaging lines 
• Accessible handling equipment at each workstation 

These workflow considerations can result in significant time savings. 

Train Staff Thoroughly and Consistently 

Equipment only helps when used correctly. Train all operators on proper handling techniques, equipment operation and safety procedures. Ideally, training will also be an ongoing, rather than a one-time event. That’s because new staff will enter the business, and you don’t want training to be forgotten. 

It’s also important to include material-specific guidance in training, as different items require different approaches. 

Maintain Packaging Equipment Proactively 

Material handling equipment needs regular maintenance. Check vacuum systems for leaks, inspect lifting mechanisms for wear, clean components regularly and replace parts before they are worn down. Schedule maintenance during planned downtime to avoid unexpected breakdowns. 

Keep spare parts on hand for quick repairs. Document maintenance activities to track equipment condition and identify recurring issues.  

Measure and Monitor Performance 

Track metrics that matter. Monitor injury rates, handling-related delays, material damage incidents and changeover times.  

If roll changeovers remain a bottleneck despite improvements, investigate additional solutions. If one area shows strong results, apply similar approaches elsewhere. 

TAWI’s Packaging Case Studies 

Many facilities have solved material handling challenges. Case studies provide practical examples of what works in real operations.  

Explore TAWI’s case studies to see how different facilities approached their material handling challenges and discover solutions worth considering. 

Moving Forward with Smarter Material Handling 

The packaging industry continues evolving. Labour shortages, SKU proliferation and demand volatility represent the new operating environment rather than temporary issues. Facilities adapting their material handling approaches gain competitive advantages through speed, safety and flexibility. 

Improvement does not always require massive capital investment. Start with the biggest bottlenecks. Address the most physically demanding tasks. Learn what others have done. Measure results and refine your approach. 

Material handling might not be the most glamorous part of packaging operations, but it is fundamental to everything else. Plants getting it right run faster, safer and more profitably, which is why it is worth exploring packaging automation systems. 

Those failing to adapt face ongoing struggles with costs, delays, and workforce issues. 

For more information on packaging material handling solutions, visit the packaging industry solutions page.