Digital technologies improve production line management and enhance data quality, while Artificial intelligence creates new opportunities for analysis, predictive evaluation and process optimization. Sustainability, meanwhile, guides design decisions toward solutions that are more consistent with the needs of the market, the environment and consumers.
by N.S.
2030 will mark a key milestone for the application of many requirements introduced by the PPWR (Packaging and Packaging Waste Regulation). Along this transformation process, European regulations and packaging technologies will play a decisive role in shaping the future of the industry.
Design for Recycling, the Digital Product Passport (DPP), Digital Twins, generative artificial intelligence, collaborative robots and AMRs, data management, digitalization, format changeover and cybersecurity are strengthening human skills and operational capabilities, while delivering the tools that make. These technologies are making production lines more suitable for new manufacturing and regulatory requirements.
Stefano Marelli from the Research and Development division of Cama Group guides us through the key stages of the 2030 Roadmap. It is a journey toward the future, where sustainable packaging is driven by the integration of innovation, methodology and industrial responsibility.
Design for Recycling: a more sustainable future for packaging
The future of packaging is guided by the Design for Recycling concept, which is central to the PPWR (Packaging and Packaging Waste Regulation). Packaging design is now conceived as part of a circular system, where every design decision has an impact on collection, sorting, recycling and reuse processes. The Design for Recycling approach favors mono-material structures, simplifies layer separation and promotes the use of inks and adhesives compatible with existing recycling technologies.
Mandatory recycled content in plastic packaging
The PPWR has introduced progressive mandatory quotas for recycled content in plastic packaging materials. By 2030, PET beverage bottles will be required to contain at least 30% recycled plastic, increasing to 50% by 2040. For food-contact packaging, the targets are 10% by 2030 and 25% by 2040, while non-food packaging will be required to reach 35% and 65% respectively. For materials such as glass, aluminum, paper and cardboard, European regulations focus more on recycling targets (for example, 85% for paper by 2030) rather than on mandatory recycled content requirements.
Digital Product Passport (DPP): the product becomes transparent
The Digital Product Passport (DPP) is set to become a European standard for tracking, managing and presenting products on the market.
“The DPP is based on the principle that every product should be supported by a true digital identity containing structured, accessible and verifiable information, such as production batch, origin, ingredients, processing stages and materials used for packaging,” explains Stefano Marelli.
“These pieces of information are made available through barcodes or QR codes applied to the packaging using laser marking systems or integrated in-line printing technologies. The manufacturer defines which data must be included, while technology suppliers provide the tools needed to generate and make this information accessible. Many of these details are already present on labels today, but the DPP represents a further evolution because it requires an additional step: collecting data within a coherent, standardized and easily accessible system. This means integrating data management, traceability, marking and process control into a path where digitalization, compliance and transparency become part of the product’s value.”
Digital twins and Generative Artificial Intelligence: the future of machinery
The digital twin is one of the most advanced tools for managing and optimizing industrial machinery. Originally developed as a simulation system to verify performance and design compliance, it has evolved into an operational platform that supports operators in the daily management of machines.
“Today, the digital twin brings together maintenance procedures, format changeover operations, component replacement instructions and electrical and pneumatic diagrams within a single environment, becoming a centralized access point for information that can be consulted quickly and contextually. Integration with augmented reality and virtual reality in Cama machines makes this information immediately accessible,” explains Marelli.
“Its ease of use is essential, even though it is supported by highly advanced technological complexity. Through tablets or smartphones, instructions can be superimposed over the machine to deliver intuitive graphical guidance exactly when intervention is required.
“The integration between digital twins and artificial intelligence has led to the development of highly advanced predictive maintenance systems, too. By continuously analyzing operating parameters and component wear, it is possible to identify signals that anticipate potential failures. This makes it possible to intervene before machine downtime occurs. The human role remains central: the digital twin supports operators with clear, timely and contextual information, acting as a digital partner that makes human-machine interaction particularly effective.”
Collaborative Robots and AMRs for production process organization
Technological evolution is transforming the entire production process, improving not only overall efficiency but also operational ergonomics.
“The introduction of collaborative robots and autonomous handling systems, such as Autonomous Mobile Robots (AMR) makes it possible to rethink intralogistics processes, overcoming the need to keep materials and components constantly available on board the machine.”
Packaging materials can be managed in a centralized way and transferred where needed when required. In this context, collaborative robots are used together with AMRs to load machines and then palletize finished products, making them available for the next stages of the process. This work organization reduces the physical workload for operators and frees up their time for higher-value activities and decisions, delivering particularly positive results in terms of workplace ergonomics,” explains Marelli. “Technology does not replace people but enables them to work more effectively.
“As far as technical support is concerned, the future is increasingly focused on the use of intelligent and predictive models. Remote connection to machines makes it possible to intervene without requiring a physical presence. In addition, artificial intelligence-based systems can analyze real-time and historical operational data to identify potential issues and suggest solutions in advance.”
Advanced technologies such as neural networks, which are becoming increasingly close to everyday industrial use, make it possible to recognize patterns and correlations that are difficult for the human eye to detect, improving intervention accuracy. Thanks to data analysis, artificial intelligence and neural networks, it is possible to identify critical issues earlier and suggest solutions faster. Contextualized data is now a strategic resource for making interventions faster, reducing machine downtime and improving production continuity.”
Data and digitalization: the value of human expertise in the future of industry
Future industry will become increasingly advanced, but human expertise will remain a decisive element. The skills of technicians, developed through direct observation and process knowledge, are essential for interpreting machine behavior.
Augmented reality and virtual reality are operational tools already being used to guide technicians during interventions to reduce downtime. “The future is increasingly focused on data management. Machines generate large amounts of information, but value comes from the ability to aggregate, structure and interpret it. The goal is to transform data into useful insights for improving production, technical support and operational continuity. Advanced analysis makes it possible to identify correlations, trends and critical issues that are not immediately visible.”
“To be truly effective,” Marelli continues, “it is also necessary to consider the operating context. Materials, temperature, humidity and the presence of dust can significantly affect plant performance. These are physical variables that influence material processability, process stability and machine behavior.
“For this reason, data analysis must also take environmental and production conditions into account. By investigating these parameters through advanced analytical tools guided by human expertise, it is possible to obtain a precise view of the process. This supports the design of more efficient and higher-performing machines while also providing customers with increasingly effective technical support.”
The evolution of format changeovers: reduced downtime through augmented reality and automation
Increasingly varied and diversified demand affects production batches and makes format changeover operations more demanding, becoming an essential activity for meeting consumer expectations. In the past, this operation required complex interventions that were largely manual. Operators had to consult the machine panel, identify the necessary adjustments, act on different components and repeatedly verify the correctness of each step. Format changeovers depended heavily on operator experience and required time, precision and constant attention. Any uncertainty could extend line downtime and reduce the overall efficiency of the production system.
“Today, format changeovers are guided, intuitive processes fully integrated into machine logic. The most advanced technologies support every stage of the operation, indicating what to do, when to do it and where to intervene. This reduces complexity, increases precision and makes format changeovers faster and more repeatable,” explains Marelli.
“Augmented reality and human-machine interfaces make access to information faster. Through a tablet, operators can consult operating instructions, technical documentation and adjustment parameters and overlay them directly on the machine at the precise point where the intervention must be carried out. The direct connection with the controller makes it possible to guide operations safely, reducing errors and intervention times.”
The result is a faster, more repeatable and safer format changeover process. Machine downtime is reduced, procedures become standardized and the risk of error decreases. Supporting this evolution are tool-less solutions, designed to make every operation simpler, more ergonomic and more efficient, together with sensor technologies that make it possible to verify the correctness of interventions in real time.
“The advantages are concrete: line downtime is reduced, procedures become more standardized and the risk of errors decreases. Tool-less solutions complete this evolution. They make operations simpler, more ergonomic and safer, helping operators work with greater precision and less effort. Every manual operation is designed to be ergonomic, natural, intuitive and controlled. In an increasingly automated production environment, ease of use is not a secondary detail. It affects line efficiency, process continuity and the quality of the final result.” He continues by explaining: “Looking ahead, format changeovers will become increasingly faster, guided and integrated into digital factory systems. The real challenge will be enabling operators to access the right information at the right time and exactly where it is needed. This is the key to making modern production more efficient, flexible and safe.”
Cybersecurity in packaging: protecting industrial machines and data
The digitalization of industrial machines increases efficiency, control and data availability, but, at the same time, it makes cybersecurity a central issue for the packaging industry and for manufacturing.
“In increasingly connected production systems, protecting information and processes has become a priority. Data related to production, machine performance and machine usage can be accessed directly on the machine, shared through cloud platforms or exported for further analysis.
“This provides a significant operational advantage, but it also requires adequate levels of security. Industrial data may contain sensitive information regarding know-how, production volumes and the operating methods of production systems. Protecting this information means safeguarding intellectual property, preserving company competitiveness and ensuring production continuity,” explains Marelli.
“Cybersecurity applied to industrial machines comprises a combination of technical and organizational measures, including user authentication, role-based permissions, firewalls, hardware and software barriers, secure remote connections and access traceability.
“One essential principle is network segregation. This technique divides the infrastructure into smaller and isolated subnetworks. In this way, the potential scope of cyberattacks is limited, sensitive data is protected and traffic control is improved. If a breach affects one network segment, segmentation prevents the issue from spreading throughout the entire production system.”
Cybersecurity must not impede daily operations. Production, maintenance and technical support must remain accessible, but only through controlled, authorized and monitored systems. Technicians must be able to intervene, especially when production continuity must be guaranteed. However, this access must take place through secure, protected and traceable connections.
Traceability is, in fact, a decisive element: every access, modification or intervention performed on the system must be recorded to ensure transparency and control. In this way, cybersecurity will not become an obstacle but, instead, a tool that increases machine reliability and simplifies the management of activities carried out on the production system.
In packaging machines, cybersecurity is an integral part of the design process. It is no longer an afterthought, but a structural component. Its role is to support the growing connection between machines, company systems and digital platforms, while ensuring operational continuity.
In an increasingly interconnected industry, protecting data and systems means protecting the value of the entire production process. The real challenge is to develop solutions capable of combining security, efficiency and ease of use, allowing companies to operate safely without compromising performance.
