How automation is transforming efficiency, sustainability and shelf appeal in pet food packaging

Automation is currently transforming the pet food packaging industry as it allows companies to achieve faster and more consistent throughput. Automation innovations enable companies to keep costs low while producing sustainable pet food packaging without reducing premium shelf appeal.

The UK pet food industry continues to grow at pace.UK Pet Food estimates 60% of households in the UK now own a pet, up from 40% of households in 2015-16. Pet food manufacturers have been turning to automation in order to keep up with rising demand.Robotics, smart inspection systems and flexible packaging lines enable manufacturers to handle diverse SKUs, reduce waste and meet retailer and regulatory requirements.

This article explains why automated solutions are now essential to compete in a high-growth, innovation-driven sector, and how AIR’s technology directly supports these outcomes.

The changing landscape of the pet food industry

The pet food industry has changed dramatically over the past decade. Not only has the number of pet owners in the UK increased, but the purchasing habits have changed as well.

Pet owners are becoming increasingly conscious of what they are feeding their pets, so there’s been a need for manufacturers to increase variety. The introduction of tailored pet food, particularly for dogs and cats, has also widened the product range. There’s been more focus on convenience formats such as resealable pouches andrecyclable pet food packaging.

Today,pet food packagingmust do more than protect the product. It must have strong shelf appeal to stand out from the competition, align with sustainability targets, and meet ever-tightening regulatory requirements. This is happening while manufacturers face rising costs in almost every department.

How automation improvespet food packaging

Automation can be transformative for manufacturers looking to deal with these changes within the industry. Automation helps pet food brands achieve faster throughput and consistent quality. It allows them to reduce fundamental costs while supporting sustainability goals and delivering premium shelf appeal.

Faster throughput, consistency and reduced costs

Everypet food packagingsystem invented by AIR is designed to operate at high speeds and high volumes to increase productivity and production line efficiencies. They are designed to operate without reducing the quality of the packaging. The packaging is far more consistent compared to traditional methods. The following high-quality elements are designed to operate at speed.

• Carton erectors
• Carton loading (top and end load)
• Carton closers
• Case erectors
• Case closers
• Custom robot loaders

Automation systems can operate continuously, with minimal downtime. Reducing the amount of downtime helps ensure manufacturing companies can meet tight deadlines and are not troubled by unexpected interruptions.

Automation reduces costs at multiple stages of the production process. Robotics reduces reliance on manual labour, meaning labour costs can be cut.

There is a high amount of inconsistency when manufacturers use traditional methods or semi-automated processes. Advanced automated lines operate with greater consistency. Each pack is filled, sealed and presented to the same standard, reducing costly rework.

Intelligent monitoring systems can identify faults and problems early. This allows for rapid intervention to correct issues before excessive product waste occurs. It also means the problem can be solved before it develops into something more significant, which leads to longer downtime.

In a competitive sector where margins are under pressure, automation enables pet food manufacturers to reduce operational costs while delivering consistent, high-quality packaging.

Robotics

Robotic systems are used in the packaging process. Custom robot loaders (2,3 & 4-axis systems) ensure the packaging machine is flexible enough to suit the production line. The robot loaders range in axis systems to undertake packing and placing tasks.

This is particularly helpful inpet food packagingbecause it means manufacturers can deal with the variety of different product types and packaging formats. As product innovation accelerates, the packaging systems must keep up. This flexibility is key to allowing manufacturers to adapt to product changes without extensive reconfiguration.

Smart inspection systems

Smart inspection systems allow manufacturers to ensure compliance with strict regulations. A regulation breach can put the safety of pets and pet owners at risk, so it’s imperative that these are followed. A mistake can also result in significant fines, which can harm a company financially and damage its reputation.

Automation systems include a polished labelling system. These modules apply labels at multiple stages of the supply chain. The serialisation systems ensure products can be tracked and traced at each stage of the process. If a product recall is required, the system can support a fast and efficient response.

How automation helps createsustainable pet food packaging

Sustainability has moved to the forefront over the past decade. It is no longer a secondary consideration. It’s now a major priority, with some retailers setting ambitious targets as a way of standing out against the competition.

Automation systems are designed to operate with energy efficiency in mind. Through optimised processes, our machines lower energy consumption compared to traditional methods. In combination with waste reduction, the overall carbon footprint improves.

Automation systems can be built to suit the orientation of the desired packing format for pet food. The system can work withrecyclable pet food packagingto support a company’s sustainability goals. AIR are focused on developing innovative and sustainable solutions to allow businesses to reduce theirreliance on single-use plastic.

How automation reduces waste in thepet food packagingindustry

Reducing waste is a top priority from an environmental and economic perspective. When waste is reduced, manufacturers can lower the consumption of raw materials and energy. This naturally drives down the overall cost of the entire production process. Reducing waste also makes the entire process more efficient.

Automatedpet food packagingsystems incorporate carton closers, which safely secure the product within its packaging. The system offers high-quality sealing to ensure the product and packaging maintain high standards.

Our case closing modules have the ability to seal packaging with tape, glue and Amazon Hybrid methods. These modules operate with high levels of accuracy, reducing the amount of poorly packaged and damaged products.

How AIR supports pet food manufacturing

AIR designs and delivers advanced automated systems to provide pet food processing and packaging solutions. Our systems are designed to improve production rates and product quality.

Regulatory requirements are frequently changing and often becoming stricter. We have experience in designing machines to meet regulations outlined by theFood and Drug Administration (FDA) and Goods Manufacturing Practice (GMP).

Our automation systems are designed to be flexible and can be adapted to meet variouspet food packagingrequirements. Speak with one of our specialists to discover the potential of automation for your business.Get in touchtoday.

AIR Wakefield

AIR Wakefield, formerly Sewtec.

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