| LYNN HEDIGER Vice President of Product Management Orbis Corp. |
JOHN LAWN Strategic Business Unit Director, iDim Rice Lake Weighing Systems |
WILLIAM NELSON President, North America E80 Group |
J WELCH Strategic Account Manager, Intralogistics Regal Rexnord |
Q: HOW WOULD YOU DESCRIBE THE CURRENT STATE OF THE PACKAGING AUTOMATION INDUSTRY?
William Nelson – E80: The industry is moving very quickly from stand-alone automation toward fully integrated systems. For years, manufacturers often automated one process at a time: a palletizer here, a wrapper there, an AGV [automated guided vehicle] fleet somewhere else. Today, particularly in the CPG [consumer packaged goods] industry, companies are looking at the entire material flow and asking how all those operations can work together as one system.
This is why we are seeing more customers look for long-term technology partners rather than individual equipment suppliers. The conversation increasingly starts with the overall process: What does the plant or distribution center need to accomplish today, what will it need to accomplish five or 10 years from now, and how can automation provide the flexibility and scalability to support that growth?
J Welch – Regal Rexnord: Packaging automation continues to evolve as manufacturers adapt to e-commerce growth, faster fulfillment expectations, and more dynamic product portfolios. As a result, companies are prioritizing flexible, scalable automation that can quickly accommodate changing packaging formats, production demands, and distribution models.
Q: WHAT MAJOR INNOVATIONS IN PACKAGING AUTOMATION HAVE YOU SEEN IN RECENT YEARS?
J Welch – Regal Rexnord: Right-size packaging systems and shuttle-based AS/RS [automated storage and retrieval system] solutions have transformed how manufacturers optimize packaging, warehouse space, and fulfillment efficiency. At the same time, increased automation adoption has heightened the need for integrated systems that seamlessly connect material handling, packaging, and warehouse operations.
William Nelson – E80: One of the most important developments has been the integration of robotics, autonomous material handling [equipment], advanced software, and real-time data into a single operating ecosystem. Software has therefore become fundamental. Instead of simply controlling individual machines, an integrated software platform can manage material flows across the entire facility, exchange information with production systems and the customer’s ERP [enterprise resource planning system], dynamically assign missions to vehicles, manage storage and retrieval, coordinate shipping priorities, and provide complete traceability.
Another major advancement is simulation. Before installing equipment, we can now create a digital model of the customer’s operations, test different layouts and production scenarios, identify potential bottlenecks, and validate control strategies. That significantly reduces implementation risk and gives customers much greater confidence that the system they are investing in today can support their future requirements.
Q: WHAT PROBLEMS ARE CUSTOMERS TRYING TO SOLVE WITH YOUR PRODUCTS?
John Lawn – Rice Lake: Manual measurements are time-consuming and often inaccurate, especially for irregularly shaped packages. Weighing and dimensioning systems calculate results in seconds and deliver more reliable measurements.
Q: WHAT ROLE DOES REUSABLE PLASTIC TRANSPORT PACKAGING PLAY IN AUTOMATED WAREHOUSING, FULFILLMENT, AND MANUFACTURING OPERATIONS?
Lynn Hediger – Orbis: As companies add more automation in their fulfillment, distribution, and manufacturing operations, repeatability and consistency are important because automated systems are engineered around very defined tolerances. Designed for long service, reusable plastic packaging can maintain its critical dimensions and performance characteristics throughout its entire service life. As automation evolves, companies are looking at reusable packaging as integral assets in their automated ecosystem, helping support the reliable movement, storage, and handling of goods.
Q: ONE OF THE TRICKIEST PARTS OF PACKAGING DESIGN IS FINDING THE OPTIMAL BALANCE BETWEEN PRODUCT PROTECTION AND PACKAGE WEIGHT. WHAT CAN SHIPPERS DO TO FIND THAT BALANCE?
J Welch – Regal Rexnord: Achieving the right balance requires understanding both product protection requirements and customer expectations. Testing and simulation tools can help manufacturers validate packaging designs, reduce material usage, and maintain product integrity throughout the shipping process.
Q: HOW HAVE DIM WEIGHT CHARGES FOR PACKAGES AFFECTED THE NEED FOR ACCURATE WEIGHT AND DIMENSIONAL DATA?
John Lawn – Rice Lake: With LTL [less-than-truckload] carriers charging by density, more shippers need to have accurate data on their packages’ weights and dimensions. LTL carriers are now auditing more frequently, and if a shipment is improperly declared, shippers can face costly chargebacks or fees.
Q: THERE ARE SO MANY CHOICES FOR PACKAGING AUTOMATION. WHAT FACTORS SHOULD BUYERS CONSIDER WHEN MAKING PURCHASING DECISIONS?
William Nelson – E80: I would encourage buyers not to begin with the technology. Begin with the process and the long-term business objective. A very sophisticated machine can solve one problem while unintentionally creating another somewhere else in the facility. Buyers should understand their complete material flow, expected throughput, SKU [stock-keeping unit] mix, available space, labor requirements, and future growth before selecting individual technologies.
Scalability is another major factor. The best solution is not necessarily the system with the highest theoretical performance today but rather the one that can adapt as the customer’s business changes.
Finally, I would look closely at the supplier itself: its engineering capabilities, installed base, simulation capabilities, service organization, and ability to support the system throughout its lifecycle. Automation is a long-term investment. The relationship with the technology partner should be considered in the same way.
J Welch – Regal Rexnord: Successful automation investments start with a clear understanding of operational challenges, long-term business goals, and future growth requirements. Partnering with experienced automation experts like Regal Rexnord ensures technology decisions align with both current needs and long-term scalability.
Q: WHAT ITEMS CAN BE MEASURED BY A DIMENSIONER?
John Lawn – Rice Lake: Dimensioners are typically designed for measuring either pallets or parcels. We offer dimensioning systems for both needs, capable of dimensioning unevenly stacked pallets or irregularly shaped parcels.
Q: HOW CAN QUALITY EQUIPMENT COMPONENTS ASSURE HIGH RUN TIMES FOR AUTOMATED PACKAGING SYSTEMS?
J Welch – Regal Rexnord: High-quality components reduce maintenance requirements, improve system reliability, and lower total cost of ownership over the life of the equipment. Buyers should evaluate long-term performance, serviceability, and workforce training requirements rather than focusing solely on upfront capital costs.
Q: WHAT IS THE BIGGEST MISTAKE COMPANIES MAKE WHEN APPROACHING AUTOMATION?
William Nelson – E80: The biggest risk is approaching automation as a series of independent projects without first developing an overall plan. We believe the better approach is to start with an overall design, understand the flows, simulate the future requirements, define the architecture, and then establish a roadmap.
You do not have to automate everything on day one. But you should know how everything you automate today will fit into the factory or distribution center you want to operate tomorrow.
Q: WHAT ARE THE ADVANTAGES OF USING IN-LINE WEIGHING AND DIMENSIONING SYSTEMS?
John Lawn – Rice Lake: In-line measuring with in-motion checkweighing systems such as [Rice Lake’s] MotoWeigh reduces the chance of accidentally giving away product or short-selling customers. Dimensioning products early in the process helps workers select properly sized packaging options, boosting efficiency and reducing waste.
Q: WHAT ROLE DO AUTOMATED MOBILE ROBOTS AND AUTOMATED GUIDED VEHICLES PLAY IN TODAY’S HYPERCONNECTED PACKAGING, WAREHOUSING, AND FULFILLMENT OPERATIONS?
William Nelson – E80: This is where mobile automation can fundamentally change the way a facility operates. LGVs [laser-guided vehicles] and AGVs eliminate the need for many fixed connections between processes. They can collect finished pallets directly from palletizers or wrappers, transport packaging materials to production, feed warehouses, retrieve finished goods, stage orders, and move pallets toward shipping.
Because the vehicles are coordinated by software rather than dedicated to one fixed route, missions can be dynamically reassigned according to production requirements and priorities. That provides considerable flexibility and helps eliminate bottlenecks. The final step is automated truck loading and unloading. LGVs can move pallets from production or storage through staging and directly into the trailer.
J Welch – Regal Rexnord: AMRs and AGVs can create flexible connections between packaging, warehousing, and fulfillment operations by automating material movement and reducing manual transport tasks. When integrated with WMS [warehouse management systems] and ERP systems, they help streamline workflows, improve labor utilization, and support scalable automation strategies.
Lynn Hediger – Orbis: These vehicles depend on consistency. By design, reusable transport plastic packaging is standardized, and it provides a predictable and repeatable interface for AMRs and AGVs. Consistent dimensions and handling features ensure that automated equipment engages with these totes and pallets to reduce variability that can disrupt automated processes.
Q: WHAT ADVANCEMENTS WILL WE SEE IN THE NEXT GENERATION OF AUTOMATED PACKAGING TECHNOLOGIES?
J Welch – Regal Rexnord: The next generation of packaging automation will leverage AI (artificial intelligence]-driven analytics, predictive maintenance, and intelligent production optimization to improve efficiency and reduce waste. These technologies will help manufacturers make faster, data-driven decisions across production, packaging, and fulfillment operations.
William Nelson – E80: I believe the next major advancement will be greater intelligence at the system level. We will continue to see improvements in robotics, sensing technologies, autonomous navigation, and AI, but their greatest impact will come from combining them with increasingly sophisticated orchestration software.
Future systems will use much more operational data to anticipate changes, dynamically optimize flows, and help companies make better decisions in real time. Simulation will also become increasingly important, not only during the original design phase but throughout the lifecycle of the facility as companies evaluate new products, production volumes, and expansion scenarios. Flexibility will be critical. Organizations need automation platforms that can evolve without requiring them to redesign the entire operation every time their business changes.
Q: WHAT WILL YOU BE SHOWCASING THIS YEAR AT PACK EXPO?
J Welch – Regal Rexnord: At Pack Expo, Regal Rexnord will showcase solutions designed to maximize throughput and uptime through reliable conveyance, optimized accumulation, and reduced maintenance requirements. Highlights include our patented ModSort Divert and Transfer technology, which enables efficient diverting, transferring, and sorting of multiple package types across both new and existing conveyor systems. [Editor’s note: Regal Rexnord will be exhibiting at Booth S-2174.]
John Lawn – Rice Lake: We will be showcasing iDimension dimensioning systems for pallets or parcels and MotoWeigh in-motion checkweighers and platform scales for weighing shipments. Our scale experts will be providing live demos throughout the event. [Editor’s note: Rice Lake will be exhibiting at Booth N-5265.]
Lynn Hediger – Orbis: Orbis is showcasing a variety of reusable packaging solutions, with a strong focus on its products designed specifically for automated operations. This includes the Odyssey pallet family. This line of 40 x 48 pallets helps improve material handling efficiency, support automation initiatives, and reduce the total cost of ownership compared to traditional limited-use wood pallets.
We will also feature the AROS tote family. This portfolio includes a wide range of totes engineered for automation, including the ML6545-325, the ML6040-325, and the collapsible MLN6040. Orbis is also an official bin supplier to AutoStore and will feature AutoStore bins. They are designed to maximize storage density and enhance picking efficiency. [Editor’s note: Orbis will be exhibiting at Booth LU-6702.]
William Nelson – E80: Our focus will be on showing CPG decision-makers what becomes possible when automation is considered as a complete intralogistics ecosystem rather than a collection of separate technologies. Visitors will be able to explore E80 Group’s capabilities across robotic end-of-line automation, LGVs and AGVs, high-density automated storage, picking and distribution center solutions, automated truck loading, and the SM.I.LE80 software platform that integrates and controls these operations.
We also want to talk about what happens before equipment is installed. Our consulting and simulation capabilities allow us to model existing and future operating scenarios, evaluate layouts, identify bottlenecks, and validate system performance before implementation. For customers making major automation investments, reducing project risk at the design stage is increasingly important. There is no universal automation solution. The right starting point is understanding where the company is today and where it wants to go, and designing a roadmap that allows the technology to evolve with the business. [Editor’s note: E80 will be exhibiting at Booth N-4738.]
