Load stability and sustainability present a challenge for end-of-line packaging.
The end-of-line packaging sector has undergone significant transformations in recent years. In an interview, Hubert Verheul from Tallpack provides insights into the challenges and technological advancements shaping the industry. Today, the focus is not only on enhancing pallet load stability but also on sustainability, energy consumption, and packaging line flexibility.
“One of the biggest challenges for end-of-line packaging machines lies in load stability, recycling, and reducing carbon footprint,” says Hubert Verheul. “Customers increasingly ask how they can maximize packaging stability while minimizing material use and employing sustainable materials. The quality of recycled materials plays a key role here; if it’s insufficient, pallet loads can become unstable.”
Energy consumption has also become a critical area of focus. Innovations like energy recovery within packaging machines are being adopted more widely. Verheul cites an example with stretch hood machines, where energy generated during downward movements is stored and reused. Similar to energy recovery in electric cars, this enables 24V systems to function without extra power consumption.
Efficiency Through Innovation
End-of-line packaging machines now need to be not only more sustainable but also more energy-efficient. Verheul notes that traditional heat-shrink systems are increasingly being replaced by stretch hooding, largely due to energy savings. Stretch hoods are 20% lighter than shrink hoods and use a memory function that allows the film to fit tightly around the pallet after stretching. In many cases, companies can recoup their investment in new packaging lines within a few years through energy cost savings. However, shrink hoods remain essential in certain sectors, like glass, where the shape and stability of round items on pallets can pose challenges.
Flexibility and Ease of Use
Packaging line flexibility is more important than ever, Verheul asserts. Packaging shapes and formats change rapidly, often driven by environmental considerations and consumer demands. “End-of-line packaging systems must be agile enough to quickly adapt to changes in primary and secondary packaging,” he explains.
Labor shortages have also become a factor. With more operators coming from abroad, machines need to be user-friendly and offer multilingual functionality. Modern packaging lines are equipped with large, intuitive touchscreens that allow operators to switch easily between languages like Dutch, Polish, and English. Alarms and control menus also include pictograms and visual instructions to facilitate machine operation, regardless of the operator’s language or background.
Automation and Robotics
Robotics and automation have become deeply embedded in the packaging industry. Smaller, more affordable robots and cobots are increasingly used to perform repetitive or complex packaging tasks. Actions that previously required complex mechanical systems can now be performed by robots.
Vision systems with cameras enable robots to handle products with varying shapes for palletizing. “In the past, this required a human’s instinct, but now machine learning is taking over,” Verheul explains. Cameras are also used to monitor critical processes within packaging lines and prevent errors.
Paper and Recycled Materials
Verheul sees a shift toward using more paper packaging, especially for lighter products. Plastic packaging, however, will continue to play a role, particularly in heavy industries like steel and construction. The use of recycled plastics aligns with EU mandates requiring companies to use at least 50% recycled materials by 2030. Trials with 100% recycled content are underway, though Verheul cautions that achieving 100% is challenging due to inevitable material loss.
Artificial Intelligence
Although artificial intelligence (AI) has yet to make a major impact in troubleshooting within the packaging sector, Verheul sees potential for AI in maintenance processes. AI could help develop maintenance schedules and optimize machine components based on usage data. For troubleshooting, Verheul expects virtual reality (VR) to play an important role, allowing technicians to guide operators remotely in resolving issues. This technology, which uses a helmet with an integrated camera and microphone, is already being tested at Tallpack.
An Evolving Industry
“The end-of-line packaging industry isn’t standing still,” Verheul remarks. “Innovations in energy efficiency, sustainability, flexibility, and robotics are driving the latest developments. While traditional systems still have a place, the future lies in intelligent, flexible solutions that help companies package more efficiently, sustainably, and cost-effectively. Innovations like AI and VR will further transform this sector in the coming years.”
