Smart Manufacturing's Role in Packaging SustainabilitySmart Manufacturing's Role in Packaging Sustainability

In an era defined by rapid technological advancement and development, smart manufacturing strategies have emerged to integrate sustainable practices within industrial ecosystems. As mentioned in an article by Forbes, including smart manufacturing practices in your manufacturing processes can lead to sustainable manufacturing systems, which would have seemed inconceivable and just simply out of the question at the start of modern manufacturing. Smart manufacturing, characterized by automation and the integration of smart technologies, holds immense promise in revolutionizing traditional manufacturing steps while contributing to closed-loop, circular systems.  

Some may call it Industry 4.0 and others might call it the Fourth Industrial Revolution, but the common consensus is that this revolution can be summed up by the scale-up of smart manufacturing. These strategies are apt to uncover patterns, predict outcomes, and optimize operations to enable a closed loop. 

Closed-loop thinking pervades all things packaging.

A closed-loop system applies sustainable principles centered on minimizing waste, maximizing resource efficiency, and promoting continuous reuse and recycling. This approach stands in stark contrast to the linear "take-make-dispose" model prevalent in traditional manufacturing, which is attributed to resource depletion. 

Smart manufacturing acts as a catalyst in the transition to closed-loop systems by leveraging data-driven insights and real-time monitoring in each stage of the production cycle. From raw material sourcing to manufacturing and distribution, smart technologies lead to more effective manufacturing management and less inefficiencies.

One of the core pillars of smart manufacturing is connectivity. As machines, sensors, and devices communicate seamlessly, monitoring is in real time. This interconnected ecosystem empowers manufacturers with actionable insights into production performance. 

Another attribute of smart manufacturing is predictive maintenance. By monitoring equipment performance and predicting maintenance needs, manufacturers can prevent costly downtime, extend the lifespan of machinery, and reduce resource consumption associated with reactive maintenance responses. 

Automation enables the rapid adaptation of production lines, streamlining workflows. Smart manufacturing has become a prevalent model in the packaging industry today. Those who work in packaging are focusing on innovations to advance circularity and industry initiatives. Smart solutions can remove roadblocks, manufacturing inefficiencies, and ultimately curb consumption. 

Streamlining processes and packaging formats.

For example, to manufacture a traditional plastic bottle, several different production processes may have to occur — production of the cap, the label, and the packaging itself may happen on separate assembly lines, increasing the complexity of the supply chain. By reducing the number of parts produced separately and choosing materials with low plastic content, the supply chain is streamlined, impacting manufacturing costs and the environmental footprint.

Consolidating components by integrating unique features like self-sealing can free packaging from the need for extra materials, like caps, closures, and/or lids. Packaging innovations that incorporate these technologies (see Aeroflexx image above) are decreasing the number of touchpoints in the production process and minimizing unnecessary plastic production and waste. (The below image provides one example.)

This flexible liquid package format can replace a bottle, simplify packaging, and offer curbside recycling capability. (Image: AeroFlexx)

Manufacturers must assess what is causing the most energy consumption in the manufacturing process to decrease energy use effectively. By taking the source of energy output into account, they can then modify it, saving many kilowatt-hours (kWh) of energy, gas, carbon emissions, and lowering waste-to-landfill potential. 

All aspects of the packaging process, from manufacturing to assembly to shipping, can be managed more efficiently by implementing smart manufacturing into the production process. The circular economy is further reinforced with the help of packaging innovations that simplify manufacturing and production processes. These smart systems can increase productivity and lower waste generation. 

Sustainable models, strategies, and systems are essential for long-term sustainability commitments. By leveraging advanced technologies, businesses can conserve resources and build resilient, environmentally safe industrial ecosystems.