The Chetan Jain Column: AI is quietly reinventing packaging

Artificial intelligence is steadily reshaping how industries operate. Its influence is already visible in daily life, from content generation and online learning to music creation and gaming. Few sectors remain untouched, and packaging is no exception.

The subject is broad enough to warrant an entire book. In fact, my own journey in the packaging industry has often intersected with technology and innovation. Over the years, I have written four books on packaging, three of which have received encouraging responses from readers. My latest book, 20 Things I Learnt from World’s Top Packaging Professionals, reflects lessons gathered through nearly two decades in the industry.

During these 19 years, technological change has been constant. Artificial intelligence is now emerging as another chapter in that journey.

AI in packaging design
One of the most immediate applications of AI is in packaging design. AI-powered tools allow designers to generate concepts quickly, experiment with layouts, and visualise packaging structures before production begins.

Generative design platforms, 3D visualisation tools, and data-driven analytics enable faster ideation while also helping to optimise material usage. This can shorten development cycles and reduce design costs.

Tools such as Adobe Firefly, integrated into Adobe Illustrator and Adobe Express, illustrate this shift. The platform enables rapid concept generation, pattern creation, and design modifications through features such as generative recolour. Designers can quickly adjust colour palettes in vector artwork or refine images by removing distractions during the editing process.

For brand owners and packaging developers, such capabilities can significantly accelerate the design stage.

AI on the production floor
Artificial intelligence is also influencing production processes, particularly in quality inspection.

Machine vision systems equipped with AI algorithms can detect defects such as misregistration, colour variation, or barcode readability issues at high production speeds. These systems help maintain consistency while reducing the risk of faulty packaging reaching the market.

Inspection systems such as Intravis SleeveWatcher are designed to identify defects in shrink sleeve applications. The system uses advanced illumination technology to minimise reflections while detecting printing or registration errors at high speed.

Similarly, inspection solutions from Silgan Equipments use high-resolution cameras and software systems to check bottles and caps for defects including skewed or missing caps. Automated inspection improves reliability and reduces the need for manual checking.

AI is also being applied in predictive maintenance. Machine learning systems can analyse machine data to forecast maintenance requirements for applicators, tunnels, and other packaging equipment. By identifying potential issues early, these systems help reduce downtime and optimise energy consumption.

Towards smarter packaging
Beyond manufacturing, AI is supporting the development of smart packaging.

Technologies such as QR codes and near-field communication (NFC) can be integrated with digital platforms to create interactive labels. These solutions enable consumers to access product information while also allowing companies to track products across the supply chain.

For packaging producers, such tools can improve traceability and enhance engagement with end users.

Adoption will take time
Despite the potential advantages, the integration of AI into packaging will likely be gradual.

Packaging production relies on established processes that evolve over time. While AI can accelerate decision-making and improve accuracy, widespread adoption will depend on factors such as regulation, labour frameworks, investment capacity, and regional industry dynamics.

Different markets will adopt AI at different speeds. For many businesses, the priority will be to introduce AI-supported tools gradually while continuing to refine existing processes.

The human role remains central
Artificial intelligence can enhance automation and improve operational efficiency, but it cannot replace human creativity and problem-solving.

Machines can analyse data and optimise processes based on existing parameters. Innovation, however, often emerges from human insight and experience. The future of packaging will therefore likely involve a balance — where AI supports decision-making while people continue to lead creative and strategic thinking.

As AI capabilities evolve, staying informed about new tools and applications will be essential for professionals across the packaging value chain.

Readers may share their thoughts or questions at info@tauruspackaging.com
.