In recent decades, automation has revolutionised industries across the globe. From automotive manufacturing to food production, the integration of robotics is reshaping how businesses operate, with the packaging sector poised for significant growth in robotic adoption.
Professor Mike Wilson, Chief Automation Officer at the Manufacturing Technology Centre (MTC) and a leading voice in industrial automation, explores how robotics is transforming the packaging landscape and beyond, offering a perspective on the future of automation in manufacturing.
Professor Wilson will be sharing his insights at the upcoming Packaging Innovations event, on February 12 & 13 at the NEC in Birmingham, where he is taking part in a session titled Predictions in Packaging Optimisation: Emerging Technology Trends for the Good of Your Assembly Line. The session promises to offer valuable perspectives on the latest advancements in automation and how businesses can leverage these technologies to optimise their packaging operations.
The Evolution of Robotics in Manufacturing
To understand where the packaging industry is heading, it’s essential to look back at how robotics has evolved. Speaking to Packaging Innovations, Professor Wilson recalls his early days at British Leyland’s Cowley factory in Oxford during the early 1980s. “At that point, Cowley only had two robots, and British Leyland had just installed the Metro line the year before, up at Longbridge, with about 15 robots on the line,” he recounts. Fast forward to today, and the same factory now employs more than 1,000 robots in producing the iconic Mini.
This exponential growth in robotics is a testament to how far automation has come in the last four decades. In the early 1980s, robots were too slow and lacked the precision needed for applications like packaging. “Nobody was using robots in the packaging sector back then. It just wasn’t being done; they weren’t fast enough or accurate enough. We still used hydraulic robots because we needed them to carry the weight on the heavier equipment. Nowadays, we have high-speed robots of various sizes and shapes that can work alongside people and vision systems that guide robots where they need to be.” Wilson explains. The advent of high-speed robots, collaborative robots (‘cobots’), and AI-powered vision systems has completely changed the game.
Addressing Fears and Misconceptions
Despite these technological advancements, the integration of robotics in packaging has not been without challenges. One of the most pervasive issues is the fear that robots will replace human jobs. “A lot of this fear has been fuelled by the popular press and science fiction films, where robots are portrayed as dangerous entities. In reality, people are starting to realise it’s not quite like that and that there are misconceptions,” Wilson notes.
He clarifies that robots are taking over tasks that are dirty, dangerous, and demanding jobs that people shouldn’t be doing in the first place. “We should be using people where their skills can add value and create more interesting jobs,” he says.
The finance industry offers a clear example of how automation can lead to job creation rather than elimination. “When ATMs were introduced, many thought that banking jobs would be lost, but instead, banks employed more people in roles requiring more skill and creativity,” Wilson remarks. This perspective is key to understanding how automation can enhance, rather than hinder, employment opportunities in packaging. “Ultimately, we need to view robots as just another piece of equipment. It’s a tool of automation, albeit more flexible and intelligent,” Wilson added.
The Rise of Collaborative Robots
One of the most notable trends in the robotics industry today is the growing popularity of collaborative robots. Unlike traditional industrial robots that require extensive guarding and infrastructure, cobots are designed to work alongside people in shared spaces. “They are becoming increasingly popular because they’re easier to install and offer greater flexibility, you can move them around the factory more easily,” Wilson says.
This accessibility is particularly important for small and medium-sized enterprises (SMEs), which represent a significant portion of the UK’s manufacturing landscape. According to Wilson, there are still tens of thousands of SMEs that have yet to adopt any form of robotic automation. “There’s a huge untapped market for robot technology, and I believe this is where we’ll see the most growth in the coming years,” he predicts.
However, he points out that most collaborative robots installed today are still working independently rather than engaging in true human-robot collaboration. “Over time, we’ll start to see more examples of genuine collaboration between people and robots, where they work closely together on shared tasks,” Wilson envisions.
The Future of Humanoid Robots
While much of the focus in automation has been on industrial and collaborative robots, there has also been growing interest in humanoid robots, particularly in China and the US. These robots are designed to mimic human capabilities and interact directly with people.
However, Wilson remains sceptical about their potential impact on manufacturing. “Personally, I don’t believe humanoid robots will have much, if any, impact on manufacturing,” he asserts. “If you’re designing a system for automation, you’ll design it in a way that standard robots can handle the tasks efficiently. You won’t need to invest in the added cost and complexity of humanoid robots unless they are required to work in environments where they must directly interact with humans and share the same space.” For Wilson then, humanoid robots are more likely to be used in those environments where direct human interaction is essential, such as healthcare or hospitality.
Overcoming Barriers to Adoption
Despite the clear benefits of robotics, there are still several barriers preventing widespread adoption in the packaging sector. One of the key obstacles in the UK has been the flexibility of the labour market. “Because we don’t typically have long-term employment contracts, as they do in parts of Europe, it’s much easier here to hire and fire people or use agency workers,” Wilson explains. This flexibility has historically deterred businesses from investing in capital equipment like robots.
However, recent factors are changing this dynamic. Labour shortages, rising employment costs, and government policies such as increases in National Insurance and the minimum wage are making automation more attractive. “There are around 50,000 vacancies in UK manufacturing alone,” Wilson points out. “Businesses are increasingly turning to automation as a solution to fill those gaps.”
Another significant barrier is the perceived cost of automation equipment. While robots are not cheap, Wilson argues that they are more affordable than many businesses realise. “You can purchase a collaborative robot and have it up and running on a production line for less than the cost of a reasonably sized family car. So, while it's not prohibitively expensive, it’s still a significant investment. Therefore, we need to ensure businesses have access to appropriate financing options, such as leasing or rental schemes, to make automation more accessible,” he says.
The Importance of Skills and Training
One of the biggest challenges in adopting robotics is ensuring that businesses have the necessary skills to operate and maintain this equipment. “Many businesses don’t feel they have the necessary expertise to procure, install, and operate robotic equipment,” Wilson acknowledges.
He stresses the importance of providing training and support to help businesses navigate the learning curve associated with their first robotic installation. “The first installation is always the hardest because it involves a steep learning curve,” he notes. By offering structured training and upskilling opportunities, businesses can better equip their workforce to handle automation projects.
Interestingly, younger generations may be more inclined to embrace robotics, as they have grown up with technology. “To younger people, robotics doesn’t seem as daunting so the hope is as more young people enter the workforce, it will likely become easier to integrate this equipment.” Wilson says. As more young people enter the workforce, Wilson also expects that this could force businesses to adopt this technology. Wilson noted, “Younger workers aren’t interested in performing the repetitive, mundane tasks that previous generations tolerated, pushing businesses to adopt automation. The younger workers are happy to work alongside robots, but prefer more engaging, high-value tasks rather than being tied to production lines.”
Navigating Geopolitical and Economic Shifts
Beyond technological advancements, external factors such as geopolitical tensions and supply chain disruptions are driving businesses to reconsider their manufacturing strategies. “We’ve already seen several external shocks in the last decade, whether it’s the COVID-19 pandemic or geopolitical tensions like the war in Ukraine,” Wilson observes. These events have highlighted the risks of relying on global supply chains and prompted businesses to explore reshoring and nearshoring options.
Brexit has also played a role in reshaping trade dynamics, making cross-border trade with the EU more complex and costly. “Businesses are realising they can’t rely on international logistics the way they used to,” Wilson adds. By investing in automation, companies can increase their resilience to future disruptions and maintain competitiveness.
Creating a Technology Plan
Wilson encourages businesses to think of automation as a strategic investment rather than a short-term fix. “It’s almost like having a business plan,” he explains. “Most businesses already have financial plans, but they also need a technology plan.”
This plan should identify relevant technologies, such as robotics and digital solutions, that can give businesses a competitive advantage. It should also outline a step-by-step strategy for implementing these technologies, considering training, financing, and long-term goals.
By approaching automation strategically, businesses can ensure they are prepared for future challenges and opportunities. “Taking that first step, thinking about automation and seeking advice, is key,” Wilson concludes. “It’s all about starting the thought process and considering how technology can support their long-term goals.”
As the packaging industry continues to evolve, embracing robotics and automation will be essential for staying competitive, addressing labour shortages, and improving efficiency. The future of automation in packaging will shape our industry for many years to come. Hear how it will influence the industry and other insights on the future of packaging from leading experts like Professor Wilson at Packaging Innovations 2025 on February 12 & 13 at the NEC Birmingham.
