How Robotics Are Reshaping the Food Packaging Industry in 2025

Convergix Marketing

Aug 7, 2025

Feature Article

The food packaging industry is critical for feeding the world’s population. However, the process is complicated by the need handle and pack food in a safe, environmentally responsible, and sustainable way in an ever-changing market.

There are other challenges facing the industry, including:

Shrinking labor force
Rising labor and material costs
Relentless push for higher efficiency
Difficult manufacturing environments
Existing facilities that are rarely designed for expansion and modernization

As a result of these challenges, many major food manufactures are beginning to embrace automation and robotics to help improve their processes. “Farm to Fork” information tracking initiatives for consumer safety and manufacturer accountability add another layer of automation requirements.

Here are four examples of how robotics and automation are being deployed in food packaging systems.

1) Robot Washdown Revolution

As demand grows for robotics in food manufacturing, major OEMs are developing robotic arms with hygienic, corrosion-resistance and IP ratings (IP67–IP69K) to withstand harsh washdown environments. End-of-arm tooling (EOAT) is also evolving to include hygienic, compliant actuators for handling irregular food shapes. In protein processing, robots must also endure Clean-In-Place (CIP) procedures involving caustic chemicals.

Automation integrators, like Convergix Automation Solutions, are leveraging these technologies to create robust robotic systems for tasks such as packaging, inspection, and palletizing, while integrating Industry 4.0 data tracking and reporting.

2) Robotic Primary Packaging and Inspection

With robotic arms and tooling now capable of withstanding Clean-In-Place (CIP) processes, tasks like tray and thermoforming loading in primary packaging are becoming more cost-effective to automate. Integrating advanced vision inspection systems into these robotic packaging lines enhances ROI by detecting defects such as broken, missing, or misshapen products before packaging.

This not only ensures product quality but also generates valuable data that can be used to improve upstream manufacturing processes and reduce waste. Food manufactures benefit from the repeatable and reliable handling of this primary packaging step.

3) Secondary Packaging

As demand grows for “Retail Ready” packaging that doubles as both shipping and display cases, robotic case packing solutions are becoming increasingly valuable. These systems offer flexibility for vertical stacking, interlocking products, and quick changeovers—key for adapting to frequent packaging design changes.

Robotics help future-proof secondary packaging operations by providing the adaptability and efficiency food manufacturers need. Quick change over gives the food manufacture more production time on the line in a 24-hour shift allowing for better optimization of the equipment and added profit to the bottom line.

4) Palletizing

Robotic palletizing has become a well-established part of the robotics industry, with OEMs offering specialized multi-axis arms and various payload ranges. Convergix enhances these systems by integrating “Track and Trace” capabilities, essential for compliance with regulations and safety standards.

These features include tracking SKUs and case numbers, building digital “Pallet Arrays,” and generating “Pallet License Plates” for plant MES systems. Automating this process reduces human error, improves traceability, and supports “Farm to Fork” initiatives by enabling efficient recalls and inspections when needed. All of this minimizes the impact to the profitability of the facility.

Convergix understands that many food manufacturing plants are older facilities not originally designed for automation, often featuring structural challenges like pitched floors, low ceilings, and limited access. By leveraging advanced simulations and 3D design, Convergix customizes automation solutions to fit these complex environments. They offer centralized, local end-of-line, or hybrid palletizing systems tailored to each facility’s layout and production needs.

Automation brings not only the ability to reduce or redeploy the current work force but increases the availability for the line. It also minimizes the amount of errors that create waste and scrap product. All of this increase the profitability of the facility and its operational effectivenes.

For more information on how Convergix can assist you in your robotic food manufacturing needs, please contact us at any time.