The UK’s food, drink, and FMCG producers face a variety of financial and operational pressures. There’s a widespread lack of confidence, with many expecting conditions to deteriorate further as global market forces and government policies take effect. And there’s little prospect of short-term improvement given the persistent inflation and budget setting. However, many manufacturers remain committed to automation, particularly in end-of-line (EOL) operations. Over half (54%) of businesses are prioritising technology investment to address skills shortages and improve productivity. Research by Food and Drink Manufacturing UK reveals that nearly three-quarters of business leaders view AI, robotics, digitalisation, and data analytics as key growth drivers. More than half have also said that they see automation and digital transformation as their top investment priority. 

Let’s explore why automation has become a strategic necessity rather than a choice for manufacturers in these sectors.

Focusing on the End-of-line

From case packing to sealing and palletising, there are various end-of-line processes. Their successful management has a direct bearing on overall production throughput, order accuracy, and delivery efficiency. Precision and speed are particularly vital, given the consumer and regulatory demands. Yet, many manufacturers remain reliant on manual end-of-line operations, with the risks of errors and delays.

Other challenges facing the food, drink, and FMCG sectors include:

• Meeting sustainability and net-zero goals
• Controlling operational costs and protecting margins
• Maintaining compliance with food safety, packaging, and traceability standards
• Responding to fast-changing consumer demands

There’s a growing realisation that such challenges can only be met through the investment in digital transformation and automation. This will require a change of approach, with manufacturers traditionally proving reluctant to make equipment upgrades.

Realising The Benefits of Automation

There are many benefits to be realised by those who adopt a positive and proactive approach to automation. Such investment reduces the risk of breakdowns, with replacement components easier to source, and less dependence on specialist engineers. End-of-line automation will support margin retention through reduced need for labour and rework, together with faster throughput. The capacity to do more with less will make a real difference, given the limited workforce availability.

Increased productivity and efficiency

Performing previously time-consuming and error-prone manual processes, automated systems allow for rapid and consistent throughput. Vacuum packaging and labelling machines can be programmed to run for as long as needed, with automatic adjustments according to demand. Automated palletisers and case packers reduce cycle times and the risks of unscheduled downtime. Such technologies also support enhanced efficiency, minimising waste, decreasing energy consumption, and ensuring optimal use of materials.

Consistency and Quality Assurance

Making for consistent standards, automated systems eliminate the risks of manual handling errors in labelling, sealing, and product orientation. The integration of advanced sensors and robotics enables the automatic checking of packaged products for improved brand consistency and compliance. AI and vision systems also allow for the real-time identification of production issues, limiting the risks of potentially costly product damage and recalls.

Labour Optimisation and Safety

Besides improving consistency, automation frees up manufacturing employees for deployment to higher-value or supervisory roles. Then there’s the improvement of workplace safety, as pallet lifters and other technologies take on physically demanding tasks. This makes for increased worker satisfaction and retention, with manufacturing organisations able to look ahead with greater confidence.

Adaptability and Scalability

There’s an expanding range of modular end-of-line systems with capacity for varying product sizes and packaging formats. Such systems are particularly suitable for mixed-SKU production lines, enabling the faster scaling of manufacturing operations and satisfaction of varying consumer demands.

Cost Control and ROI

Enhancing accuracy and minimising the risk of packaging errors, the integration of automated systems results in reduced waste. With less need for maintenance and optimisation of energy efficiency, there’s the clear potential for a rapid and significant return on investment. Expanding on the range of benefits, end-of-line systems are increasingly connected with AI for automatic fault detection and repair. We’re also seeing the widening adoption of collaborative robot handling systems, which can be relied on to work safely and efficiently alongside factory staff.

Setting the Priorities for Implementation

Analysis and planning will be vital for the full realisation of end-of-line automation benefits. This should begin with a production line audit to identify the most labour or cost-intensive activities. You’re advised to fill out an asset register, detailing the lifecycle stage and importance of each component in terms of production, safety, and compliance. There should also be some consideration of workforce capabilities, identifying the skills gaps and training needed to make best use of new systems. The automation priorities will depend on such factors as the risk of obsolescence and expected speed of return on investment.

Vital automation considerations also include:

• Capacity for products of varying formats and complexities
• Compatibility and ease of integration with existing equipment
• Reliability and availability of maintenance support
• Capital and operational costs.

Having carried out a thorough review, the best approach may be to phase the upgrades according to a roadmap. Your chosen supplier should give the assurance of tailored integration and support. There should also be confidence in maintaining the required production rate as new equipment is integrated and training is delivered.

Supporting the UK’s Producers

Automate UK plays a key role in the connection of manufacturers with trusted automation suppliers and integrators. This is achieved partly through the representation of 600+ trusted members in the product finder. From inspection machines to vacuum equipment and components, you can be sure of finding the right products in our comprehensive online directory. And you can have ultimate confidence in the BARA and UKIVA integrator standards. With in-depth technical resources and popular industry events, we have everything needed to accelerate successful automation across the food, drink, and FMCG sectors.

Join Automate UK and discover the best technologies and partners for the modernisation of your end-of-line processes.