Can AI and automation change the game in beverage manufacturing?

The use of artificial intelligence (AI) in manufacturing has entered a new era. In recent years, original equipment manufacturers (OEMs) have developed ways to use AI to assist operators through human/machine interfaces (HMIs), analyze overall equipment effectiveness in real time, and/or enable predictive diagnostics based on sensor data.

Today, OEMs and some consumer packaged goods (CPG) companies are comfortable with integrating AI tools into machinery, and the number of companies testing or preparing for limited applications has increased.

And yet, full-scale AI deployment is still uncommon.

The findings come from a new report from The Association for Packaging and Processing Technologies (PMMI), ahead of Pack Expo Las Vegas (September 29 –October 1; Las Vegas Convention Center).

Automation continues to play a vital role

Today’s beverage manufacturers face two key concerns. First is the cost of operations. Second is the availability of labor.

Automation still drives most of the gains in manufacturing efficiency, and the technical integration of manufacturing machinery will have a positive impact on beverage packaging operations in the coming years.

That’s according to the 2025 Beverage Industry Packaging Trends, which surveyed beverage manufacturers and contract manufacturers across the US.

“The integration of automation and robotics is also continuing to revolutionize packaging in the beverage industry,” said Rebecca Marquez, Director of Custom Research, The Association for Packaging and Processing Technologies (PMMI).

“For example, robots facilitate high-speed packaging, reducing human error while maintaining hygiene standards.”

In fact, an important factor influencing machinery purchases is how to improve productivity while simultaneously dealing with the challenge of labor shortages.

“For instance, automation and robotics have evolved to the point where companies can justify that it is more cost-effective over the long term to add these technologies versus the high cost of labor,” said Marquez.

“In PMMI’s 2025 Performance Optimization: Insights for Packaging Line Readiness study, more than three-quarters of the survey participants selected productivity as one of their top priorities, followed by cost and automation. While it is not surprising that participants are focused primarily on productivity and cost, the importance they place on automation in manufacturing cannot be underestimated."

The Performance Optimization report concurs with the findings from PMMI’s 2024 State of the Industry report. This study concluded that CPG companies are very interested in adding automation and robotics, with nearly two-thirds of respondents indicating they would add automation equipment, cobots, or robotics to their packaging operations in the coming year.

“Automation for palletizing and load stabilization equipment, multi-language HMIs, simplified user interfaces, visual aids for machine parts, and lockout systems are expected to become increasingly important, especially for companies facing continuing labor issues,” said Marquez.

“They are now more willing to invest in automated lines as a means of addressing labor shortages and lessening dependence on skilled workers.

“For example, machine vision can significantly reduce the need for manual labor by automating the process of sorting and placing products into variety packs.

“This trend toward automation and reducing manual labor will drive the need for sophisticated conveying systems capable of precision product handling, minimizing the risk of damage to lightweight and fragile packages. Conveying systems with advanced features, such as automated adjustments, improved tracking, and integration with other automated systems, will become business as usual.

“More companies are beginning to realize they must balance short-term, tangible benefits, such as cost savings, reduced downtime, and immediate ROI, with long-term advantages, including a scalable, future-proof solution that enhances automation, provides real-time insights, and optimizes production processes.”

But automation alone may not be enough

In addition to automation, food, beverage, and other CPG manufacturers are beginning to move toward AI technology and machine learning and want to learn more, although most projects are in the research and planning stages, according to PMMI’s 2024 Transforming Packaging and Processing Operations report.

“Early adopters are employing AI for production demand, planning, and forecasting, as well as data processing and analysis,” said Marquez.

“On the factory floor, AI is used for the automation of repetitive tasks, machine vision and quality control, predictive maintenance, remote service and monitoring, and inventory management.

“Automation, augmented reality, virtual reality, and AI are all pivotal in managing workforce limitations. By providing guidance and training, these technologies can make processes more efficient and reduce reliance on highly specialized staff.”