Competitiveness in the packaging industry is no longer just about producing faster, it is about adapting more efficiently. New packaging formats, multiple SKUs, shorter production runs, greater product customisation and increasing sustainability requirements are pushing manufacturers to adopt more flexible automation models.
In this context, Schneider Electric, a partner of the Barcelona Packaging Hub, is promoting Open Software-Defined Automation (SDA) as a way to transform production lines into more agile, modular and future-ready environments capable of responding quickly to changing market demands.
The new packaging challenge: flexibility without compromising efficiency
Today’s packaging manufacturers face constant pressure to adapt to frequent format changes, an increasing number of SKUs (references), smaller batch sizes, higher levels of customisation, and stricter sustainability and traceability requirements.
The challenge is that many production lines still rely on rigid automation systems. Every format change may require production stoppages, mechanical adjustments or software reprogramming, directly affecting productivity.
This is where Open Software-Defined Automation makes a difference. It enables manufacturers to move towards a more dynamic production model, where changeovers become part of an agile operation instead of a barrier to efficiency.
What is Open Software-Defined Automation?
Open SDA is an automation approach that separates control logic from the hardware and manages it through software.
As a result, production recipes, machine configurations and packaging formats can be handled as digital data, making production significantly more flexible, scalable and easier to adapt.
What are the benefits?
- Greater operational flexibility
- Faster format changeovers
- Reduced dependence on physical adjustments
- Less production downtime
- Better adaptability to new production requirements
Instead of relying on a rigid production line, manufacturers gain the ability to reconfigure operations quickly according to the product, packaging format or production batch.
Schneider Electric's vision for the packaging industry
Schneider Electric sees Open Software-Defined Automation as one of the key technologies for building more open, connected and adaptable manufacturing environments.
This approach is particularly relevant for the packaging industry, where manufacturers must continuously respond to an increasing number of product references, shorter production cycles and growing pressure to optimise resources.
Schneider Electric’s solution goes beyond controlling production processes. Its objective is to make manufacturing systems easier to adapt while keeping operational complexity under control.
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Faster format changeovers with less operational friction
One of the most significant advantages of open SDA is the reduction of friction during format changeovers.
On conventional production lines, switching from one SKU to another often requires production stops, technical intervention, manual adjustments and valuable production time.
With SDA, changeovers become more digital and less dependent on physical machine modifications. This allows manufacturers to:
- Reduce changeover times
- Increase productivity
- Minimise downtime
- Respond more quickly to fluctuations in market demand
For packaging manufacturers, this translates into more efficient production and greater flexibility when handling multiple product references.
Modularity for scalable production
Another major advantage of Open Software-Defined Automation is its modular architecture.
Each section of the production line, filling, sealing, labelling, inspection or case packing, can be integrated using a more open and reusable approach. This makes production lines easier to reconfigure and reduces the need for complete redesigns whenever products or packaging formats change.
Benefits of modular automation:
- Easier line reconfiguration
- Greater scalability
- Better adaptation to new packaging formats
- Reduced operational complexity
- Lower long-term operating costs
As product portfolios continue to expand, this level of flexibility becomes increasingly important.
Integration with industrial digitalisation
Open SDA is particularly effective when combined with other industrial digitalisation technologies such as Manufacturing Execution Systems (MES), Industrial Internet of Things (IIoT), digital twins and advanced data analytics.
Together, these technologies enable manufacturers to create smarter, more connected production lines with greater visibility, improved performance, enhanced quality and more efficient resource management.
In the packaging industry, where productivity and sustainability increasingly go hand in hand, this technological evolution can have a direct impact on long-term competitiveness.
The future of packaging will be more adaptable
Speed alone is no longer enough. In today’s packaging industry, competitive advantage depends on the ability to adapt quickly to changing market requirements.
The Open Software-Defined Automation approach promoted by Schneider Electric offers a clear answer to this challenge by enabling more flexible, modular and adaptable production lines capable of operating efficiently in constantly evolving manufacturing environments.
The packaging factory of the future will not only be more efficient, it will be significantly more adaptable.
If you would like to discover how Open SDA can improve the flexibility and efficiency of your packaging processes, contact Schneider Electric.
To learn more about how the Barcelona Packaging Hub can help you drive innovation and identify the most suitable technological solutions for your packaging processes, get in touch with us.