PackMach Asia Expo 2025: Packaging machinery 4.0

A panel discussion held on 14 November at PackMach Asia Expo and DrinkTec India 2025, titled, Packaging Machinery 4.0: Smart, Connected, and Agile explored the evolution of packaging lines into intelligent ecosystems. The discussion was moderated by Ainain Shahidi of 4 Sixes Packaging and Marketing and featured Dwijeesh Nair of Pidilite Industries, Sanjay Madan of Emami, and Ranjan Singh Chadha of Festo India.

The industry experts affirmed that this transformation — driven by data, connectivity, and artificial intelligence (AI) — is no longer optional but essential for modern manufacturing.

The pillars of packaging machinery 4.0
Sanjay Madan of Emami defined Machinery 4.0 as a three-step process including automation, connectivity, and agility. He noted that while automation is the starting point, true transformation occurs when all elements of the line become connected. For instance, when a finished product camera signals the initial filling machine for immediate correction, it results in a connected and agile system. 

With IoT-based systems, a production manager can now remotely monitor Overall Equipment Effectiveness (OEE), wastage, and productivity in real-time. Madan also highlighted the shift from old line speeds of 100 bottles per minute to current expectations of 600 bottles per minute, necessitating these intelligent systems.

Predictive maintenance and operational efficiency
The panel emphasised the role of predictive maintenance in minimising downtime and enhancing OEE. Dwijeesh Nair of Pidilite Industries stressed that neglecting predictive maintenance results in costs that are “multiple times more than the cost of regular maintenance,” including significant production losses, brand equity damage, and costly emergency spare part procurement. 

He noted that predictive maintenance, unlike scheduled maintenance, anticipates failure by analysing data, citing examples where sensor failure or air system leaks can lead to major compliance issues or safety hazards. 

Madan added that in the old days, skilled operators used intuition and domain knowledge to predict breakdowns, but today, smart sensors and AI take over this role by analysing data to recommend the next step required to prevent failure.

AI and the sustainability mandate
Ranjan Singh Chadha of Festo India asserted that the future is built around smart sustainable automation solutions, catering to customer demands for higher efficiency, higher OEE, and greater flexibility. 

He highlighted that technological advancements are accelerating machine delivery, with certain solutions being built for processes like palletising, where operators simply input parameters rather than waiting months for design.

Chadha also focused on sustainability, noting that the industry is moving to smarter products that conserve resources. Festo, being carbon-neutral, aims to help customers employ tools like energy audits and the energy efficiency model to analyse air consumption, detect leakages, and automatically cut off power during breaks, thereby reducing material consumption, energy use, and the overall carbon footprint. 

Madan added that AI is now taking digitisation a step further by analysing collected data and autonomously directing managers on necessary actions, removing the reliance on human analysis.

Speed, eCommerce and the skill gap
The panel addressed the challenge of adapting to the market's demand for smaller pack sizes, smaller batches, and faster product launches, especially driven by the high-value, high-speed demands of eCommerce. 

Nair explained that for new or highly complex product launches, full automation is often not viable due to the lack of immediate ROI. The solution lies in modular machines, where companies can start with semi-automatic equipment and incrementally add components — like scanning, sensors, or labelling capabilities — as they grow, allowing them to pay as growth takes place and achieve faster project turnaround times.

Addressing concerns about the workforce, Nair confirmed that while automation and robotics will replace jobs involving “mundane, repetitive activities,” they are simultaneously creating new, highly-skilled jobs related to programming, maintenance, and design. 

He cited estimates suggesting that automation could create three times more jobs in the packaging industry by 2050, albeit with different skill requirements. 

The panel discussions at PackMach Asia Expo and DrinkTec India 2025 conclusively established that the packaging sector is undergoing a fundamental digital and technological mandate, establishing its future as a highly intelligent, interconnected ecosystem where technology simultaneously drives speed and efficiency, environmental responsibility, and consumer transparency.