Despite widespread labor shortages, many CPG manufacturers report limited automation in key operations. While plans are underway to expand automation, barriers such as cost, space, and flexibility limit adoption. 
PMMI Business Intelligence: 2025 Inside the Workforce Gap
According to the 2025 Inside the Workforce Gap report by PMMI, The Association for Packaging and Processing Technologies, only 42% of CPGs currently automate loading/unloading, while even fewer have automated tasks like warehousing (23%), quality inspection (22%), and changeovers (13%). A surprising 35% reported no automation in any of the listed areas.
However, CPGs say automation usage is expected to increase. The Business Intelligence team finds that over the next 1-3 years, 64% plan to automate or expand loading/unloading, and over 50% anticipate expansion in changeovers and quality inspection.
Automation is no longer seen as synonymous with job replacement. Instead automation can help compensate for workforce shortages and make existing staff more effective, by augmenting the workforce.
Despite strong intent, many CPGs struggle with the realities of automation:
- Cost and ROI: Capital availability is limited, and uncertain payback timelines often stall projects.
- Space Constraints: Facilities must accommodate flexible SKUs in tight footprints, which limits the scope of automated solutions.
- Line Downtime: “There’s not much downtime in our business,” said one automation engineer, making phased automation more common.
For OEMs and technology partners, the opportunity lies in designing automation that supports and empowers the workforce, reducing physical strain, improving safety, and allowing staff to focus on problem-solving, quality, and continuous improvement.
SOURCE: 2025 Inside the Workforce Gap
For more insights from PMMI’s Business Intelligence team, find reports, including Inside the Workforce Gap, The New Material World: Packaging’s Path Toward Sustainability, and Food Safety and Sanitation Trends at https://www.pmmi.org/business-intelligence.
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