Flexible Packaging
The future of end-of-line automation in flexible packaging
The flexible packaging market is on a strong upward trajectory, expected to hit US$ 389.07 billion by 2032, rising from an estimated US$ 285.34 billion in 2025, says Didier Saussereau, packaging portfolio director at Sidel
Formats like stand-up pouches, chain bags, and refi ll bags are leading the growth, especially for food and beverage applications.
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Flexible packaging formats – such as sachets, bags, and stand-up pouches – off er strong visual appeal and shelf presence. However, their lightweight and deformable nature can lead to specifi c handling challenges at the end of the production line. Thanks to its adaptability, fl exible packaging is now used across a wide range of applications, from on- the-go products to ready-to-eat meals. As the food industry capitalises on these opportunities, brands are increasingly turning to end-of-line automation to enhance competence and respond to evolving market demands.
In response, the industry is embracing advanced automation, particularly robotics and cobotics. These technologies streamline operations by increasing speed, accuracy, and consistency while reducing manual handling. Cobots, designed to work safely alongside human operators, bring added fl exibility and uptime.
Unlike other types of primary packaging (such as cans, tins or cartons), fl exible packaging does not off er the advantage of a stable geometry, making it diffi cult to accumulate, seal, stack, or withstand vertical compression during packing and palletising. Their inability to hold their shape can cause major consequences for the packing process and requires particular care and attention during automation.
Maintaining product integrity – particularly for delicate items like biscuits for instance – while maximising eff ectiveness remains a key challenge for manufacturers.
To avoid damaging contents during case packing, it’s crucial to select a solution tailored to both the product and the packaging type. A one-size-fi ts-all approach rarely works; instead, manufacturers should explore a broad range of technologies including top-loading gantry systems, integrated Pick & Place robotic arms, and customised gripping tools designed to deliver gentle yet precise product collation and placement. By integrating automation into end-of-line processes, manufacturers can cut costs, reduce downtime all while meeting growing demand for customised solutions. Automation must accommodate various product shapes, sizes and fragility, often requiring customised gripping and collation systems.
SIDEL’S END-OF-LINE INNOVATIONS Sidel leads the way in end-of-line automation with a tailored approach using top-loading gantry systems, Pick & Place robots, and advanced gripping tools
his momentum is fuelled by rising consumer expectations for convenience, increasing focus on sustainability, and innovations in packaging materials.
to protect product integrity. Robotic and cobotic solutions that boost both effi ciency and fl exibility. Their modular system designs allow for rapid adaptation to diff erent packaging formats and sizes. Two standout examples of Sidel’s innovation are CoboAccess_Pal and RoboAccess_Pal_S, which apply cobotic and robotic technologies respectively to drive productivity gains.
CoboAccess_Pal is a compact cobotic palletiser equipped with a robotic arm capable of handling cases up to 14kg. With a reach of 1,700mm and the ability to stack pallets as high as 1,900mm and operates at speeds of up to six cycles per minute.
Its fenceless design ensures safe interaction, while integrated PalDesigner software simplifi es pallet pattern setup.
For higher-speed needs, RoboAccess_Pal_S combines cobotic fl exibility with robotic performance, reaching 12 cycles per minute and handling up to 25kg. With a dual-station footprint under 12 m² and fast ROI, it suits low- to medium-speed FHPC lines. Additionally, Sidel’s Cermex Robotic solution is a highly adaptable, energy-effi cient system designed for the precise handling and packing of fl exible packaging formats like sachets, stand-up pouches, and fl owpacks. It features a full range of modular loading arms to meet varying speed, payload, and layout needs, along with lightweight, custom 3D-printed gripping tools that reduce head weight by up to 30%. These robots manage product collation, fl ow control, and assortment with care, using advanced gripping technologies such as suction cups and membranes to preserve product integrity. Their intelligent design enables quick format changeovers, protects tooling, and ensures compatibility with both upright and fl at product orientations.
THE FUTURE OF AUTOMATION IN PACKAGING Through its pioneering use of robotics and cobotics, Sidel is redefi ning end-of-line automation – empowering manufacturers to tackle the complexities of modern production.
By integrating these advanced technologies into
fl exible packaging lines, Sidel delivers a signifi cant boost in effi ciency, precision, and adaptability. Faster changeovers, gentler product handling, and scalable automation make robotics and cobotics essential for meeting today’s packaging demands while future- proofi ng operations for tomorrow.
38 June 2025
www.convertermag.com
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