Packaging Trends 2026: Workflow Automation and Labour Solutions

Packaging operations are facing increased pressures from sustainability, labour shortages, unpredictable demand fluctuations, and rising packaging automation costs. 

These trends affect how facilities operate. It’s time for operations managers to rethink workflow and material handling.  

Trend #1: Labour Shortages 

The challenge of the labour shortage has been around for a while. Yet, with the shortage expected to continue, it is critical to address it. 

According to PMMI’s Inside the Workforce Gap 2025 report, 95% of packaging end users struggle to find skilled operators and technicians. This deficit of staff puts strain on current employees because they have to: 

• Work longer hours/pick up extra shifts 
• Handle increased responsibilities 
• Face greater physical demands 

Exhausted staff are more prone to making mistakes. This leads to more injuries (both minor and serious).

Also, overworked staff are more likely to look for other roles, especially less physically demanding ones. This creates a cycle where remaining staff shoulder even heavier burdens. 

Take the Weight Off of Workers’ Shoulders 

One way to address this is by reducing physical demands. Facilities can take the weight off of workers' shoulders by implementing automated packaging systems.  

Semi-automated solutions like lifting trolleys allow operators to move heavy materials like reels without physical strain. One operator can safely perform tasks previously requiring two people.  

The workforce becomes more adaptable, and facilities reduce dependence on finding operators with specific physical attributes.  

 

Trend #2: Faster Changeovers and Multi-SKU Production 

Product variety continues to expand as brands offer more and more options, each with different packaging needs. This increase in SKUs also means shorter production runs. One production line might be used for multiple products during a shift. 

Having a line switch between multiple products means different materials need to be handled. Workers must keep changing out materials to prepare for the next product. Also, changeover speed directly impacts capacity.  

Stay Adaptable: One Tool for Multiple Materials 

It’s important to maintain efficiency and avoid slowdowns, but that can be tricky with so many changeovers. To boost employee productivity, it can be beneficial to utilise equipment that can cover material handling tasks.  

With multi-SKU production, any material handling equipment needs to be adaptable to be able to handle lifting a diverse array of materials. Equipment like vacuum lifters have detachable suction feet, so one lifter can be used to lift a variety of products. 

Trend #3: The Rise of Automated Packaging Systems 

The packaging automation market is forecast to grow by billions of dollars in the next several years. Much of this growth comes from affordable, targeted automation rather than complete line overhauls. 

While many people recognise that technology can modernise systems and improve workflows, it can be difficult to decide what system is needed. 

There are systems with full automation. These robotic systems can precisely complete repeated actions 24/7 and can provide long-term labour savings. Also, they work well for high-volume production environments. 

However, the upfront capital investment can be very expensive, which can make companies hesitate. These systems are very complex, so there can be a long implementation period and long downtime if the robot stops working and needs complex repairs. 

Making Automation Implementation Practical

Compared to fully automated packaging systems, semi-automation systems have lower investment costs. This makes implementation more accessible. Semi-automated solutions also offer shorter installation times – as well as integration with existing equipment – meaning less production disruption. 

This equipment can deliver practical results for most facilities because it assists workers instead of replacing them. The equipment carries the load weight while operators control movement and positioning.  

Often, facilities that integrate semi-automated solutions start with the highest-impact applications such as palletising or roll handling. Once they measure and see results, they typically expand to additional areas. 

Did you know? Phased implementation is also an effective way of spreading costs while building internal expertise. 

Trend #4: Sustainability Packaging Trends Impact Workflows 

Sustainability is of course a key trend in packaging overall, whether it’s the use of certain materials or circularity. Some current sustainability packaging trends are brands favouring recyclable films, paper-based alternatives, and lightweight substrates. These newer materials often require more careful handling than traditional options. Also, switching between different raw materials, even if they are the same weight, can cause operational challenges. 

Materials may be lighter, but have you considered the dangers of manually handling more fragile packaging? 

The sustainability packaging trend of lightweighting materials reduces material usage but creates thinner, more fragile products. Material diversity complicates operations as facilities must handle different materials. It is important that materials are handled properly and not damaged in the process. 

Sustainable Material Handling 

Instead of relying on workers to properly grip delicate materials, equipment can offer consistency. An example is a lifting trolley that can grip a reel from the core or the outside with the right amount of pressure to maintain the package integrity. Alternatively, vacuum lifters use suction feet to handle goods with a gentle yet secure grip.  

These ergonomic tools can efficiently lift goods and minimise the risk of damage. This proves crucial for fragile, lightweight materials increasingly common in sustainable packaging. 

Trend #5: Safety as a Competitive Advantage 

Today, safety is not just a compliance requirement, but a competitive advantage among workforces. Facilities that prioritise safety and have strong safety records see many benefits like: 

Build a reputation as responsible employers 

• Attract better workers 
• Reduce pay-out costs (due to fewer safety incidents) 
• In tight labour markets, safety reputation influences recruitment success. 

To increase safety and prevent injuries, consider investing in ergonomic equipment. Workers using assisted lifting stay productive longer, make fewer mistakes, and maintain better morale. 

Harnessing Packaging Industry Trends 

These trends are shaping the way facilities operate today and in the years ahead. Labour shortages aren’t going away, product ranges are only getting broader, and sustainable packaging expectations are getting stricter. Packaging facilities that rethink how they handle materials see multiple benefits including faster operations, safer workplaces and more flexibility. 

Improving doesn’t have to mean huge investments. Start by tackling the most physically demanding tasks, focus on the bottlenecks that matter most, and explore material handling solutions. 

Need inspiration? See how organisations like yours are utilising TAWI solutions. View our case studies. 

Or if you are interested in more information on packaging material handling solutions, visit the packaging industry solutions page.