Using technology to enhance efficiency: IoT, production line efficiency, and early adoption

As we delve into the conversations with industry leaders, it becomes clear that the integration of advanced technologies, coupled with a commitment to sustainability, is essential for the future of packaging.

Dr Ainain Shahidi moderated a panel discussion between Sridhar J, head of packaging development at Pureplay Skin Sciences; Jayadev Dash, deputy general manager for packaging at Strides Pharma Science; Dwijeesh Nair, group head of packaging development for the CC division at Pidilite Industries; and Shekhar Wankhede, manager for digitalisation and automation at Zydus Lifesciences.

The panellists discussed critical themes, focusing on the role of technology in streamlining packaging processes, the challenges and opportunities presented by sustainability mandates, and the importance of collaboration between manufacturers and machine suppliers.

Role of IoT in industry

The Internet of Things (IoT) is increasingly becoming a cornerstone of modern industries, revolutionising how businesses monitor and control processes in real time.

According to Nair of Pidilite Industries, the scale of IoT is nothing short of astonishing. “By the end of 2025, there will be around 22-billion IoT devices connected worldwide,” he noted, highlighting not only the expected growth in connected devices but also the enormous volume of data they will generate. This explosion of connectivity provides unprecedented opportunities for organisations to harness real-time data for their operational needs.

One of the standout features of IoT is its user-friendly interface. Nair illustrated this with a relatable example: “If you want to pre-heat your car before you get into it, you can do that with IoT-enabled devices.” This ease of use enhances the user experience and streamlines everyday tasks, illustrating the technology's potential to improve daily life and operational processes alike.

In a specific case involving a pilot project with injection moulding machines, Nair observed actionable outcomes from IoT integration. “Once we implemented IoT, we gained credible data on time, which allowed us to improve our efficiency and productivity significantly,” he explained. This shift to real-time data analysis enabled the company to move away from solely relying on vendor claims, providing a clearer understanding of machine performance and operational parameters.

The ability to monitor machinery conditions in real time represents a paradigm shift in manufacturing processes, according to Nair. He emphasised the role of cloud computing, stating, “Cloud computing has made it possible to store large amounts of data at a minimal cost.” This capability is crucial for managing the voluminous data produced by IoT devices, supporting better-informed decision-making.

However, as organisations increasingly embrace IoT solutions, challenges remain. Nair acknowledged, “The only disadvantage we encountered was the risk of data breaches.” As connectivity increases, so do the vulnerabilities, necessitating vigilance about cybersecurity measures.

Summarising his perspective, Nair encapsulated the essence of IoT’s growing importance: “IoT is gaining significance now, especially in the last decade, and it’s essential for organisations to leverage this technology while ensuring they safeguard their data.”

Wankhede, from Zydus Lifesciences, agreed with Nair. He stated, “IoT involves devices such as sensors that connect to the Internet.” These devices play a crucial role in gathering extensive data generated by machines, equipment, and instruments.

Shekhar highlighted that the true power of this connectivity lies in its ability to streamline the entire supply chain. He noted that “the entire supply chain—from manufacturing and warehouse management to distribution — can utilise interconnected IoT devices.” This interconnectedness allows businesses to monitor every stage of a product's lifecycle, improving oversight from manufacturing through to logistics and ultimately delivering the product to consumers.

The insights derived from this data are pivotal. Shekhar asserted, “AI models can learn from this massive data pool.” He said that by utilising machine learning techniques driven by Python algorithms, these models offer insights that are often overlooked by humans. “This analysis not only uncovers hidden patterns but also facilitates data-driven decision-making.”

The implications of this technology are significant. Shekhar concluded that “this approach will enhance efficiency and significantly reduce the time required for manual processes, which often lead to missed details.” By embracing IoT and AI, companies can minimise errors, reduce machine downtime, and optimise their packaging processes, resulting in enhanced overall productivity.

Enhancing quality through technology

In the landscape of product packaging, significant advancements are being made to ensure quality and efficiency. One area that has garnered attention is the difference between blister packaging and bottle packaging processes. Shekhar noted, “The bottle packaging process is different.” This distinction highlights the unique challenges faced in maintaining product integrity during packaging.”

A unique characteristic of bottle packaging is that once bottles are capped and sealed, the conditions during packaging become largely unseen. This lack of visibility can pose risks to product quality. However, Shekhar pointed out that “thermal vision inspection systems” are emerging as a game changer. These innovative systems provide real-time data regarding the characteristics of the products throughout the packaging process. “By utilising advanced sensors and algorithms, these systems can monitor tolerances that have been predetermined during batch development,” he said.

The benefits of integrating thermal vision inspection systems are substantial. Shekhar explained, “If any deviations occur, alerts will be sent immediately.” This instantly triggers a response, ensuring that issues are addressed in real-time rather than facing delays that could compromise quality. “Such swift reactions not only enhance efficiency but also play a crucial role in maintaining product integrity,” said Shekhar.

Moreover, the use of these advanced systems has been shown to "reduce human errors," which are often a significant risk factor in manual inspection processes. By automating the monitoring of product characteristics, companies can alleviate the challenges associated with human oversight.

Packaging materials and technology

In the ever-evolving landscape of packaging materials and technology, advancements are driving the industry towards greater sustainability.

Sridhar emphasised the critical balance between sustainability and product longevity, emphasising a practical approach to biodegradability and technology integration. He stated, “I’m not a very big fan of biodegradability per se, especially regarding the shelf life of a product. Ultimately, the integrity of the product is crucial, as business sustainability is essential."

He also highlighted the importance of life cycle analysis (LCA) in sustainable practices and expressed his vision for developing low-cost technologies in South Asia. “I would love my Indian visionary friends to collaborate on creating affordable technology for our region," he noted.

One notable technology that Sridhar mentions is the innovative liquform technology. He explained, “Typically, we use a PET preform which goes through various stages before filling. However, this new method allows the bottle to be blown during the filling process itself. This integration significantly enhances efficiency — by 75% — while reducing wastage by 25%.”

Sridhar points out that this technology has already proven effective in places like Japan. He stressed, “This is a prime example of how we can streamline processes and employ integration for a more sustainable future.”

Additionally, he shares his company’s success story, the Plum brand, revolving around in-mould labelling (IML) technology. “Seven to eight years ago, we began implementing IML in HDPE and FPP bottles. It’s particularly challenging with asymmetrical bottles, like our conical body wash containers. Yet, we found a way to integrate technology with materials,” Sridhar explained.

He proudly mentioned that Plum is the first direct-to-consumer brand in India to use this method on such bottles, with IML labels made from 25% recycled materials. “We’ve eliminated the need for silicone release paper and adhesives, which enhances our quality control and streamlines our logistics,” Sridhar added.

Sridhar underscored the importance of innovative technology and process integration in creating sustainable packaging solutions. “By focusing on these advancements, we can make significant contributions towards a more sustainable planet,” he affirmed.

Pharma vis-à-vis packaging machinery

The pharmaceutical industry has undergone notable changes in the last two decades, said Jaidev Dash, deputy general manager for packaging at Strides Pharma Science, emphasising the urgent need to enhance production line efficiency, particularly in the blister packaging sector.

Dash begins by stating the critical first step: “We must observe our current production process.” This involves a detailed assessment of output, and production flow structure, and identifying any minor disruptions that could affect efficiency. To tackle these issues, he suggests, “addressing these minor stoppages,” and considers the implementation of annual interventions to enhance performance.

In a highly competitive market, timely product delivery is non-negotiable. “If we fail to deliver on time, customers are likely to reject our products,” Dash warned, highlighting the risks to the business. To mitigate this challenge, he has been investigating the incorporation of AI technology within blister lines, aiming to markedly reduce setup times. “Digital machines equipped with camera systems streamline the setup process for blister packaging,” he noted.

Historically, machine setups could take between “one to two hours.” However, with advancements in AI and auto-teaching processes, operators can now achieve faster setups without relying heavily on vendor assistance, which was once a significant time drain. Dash points out the exciting availability of various AI technologies, such as ECG systems, to support these enhancements.

Looking at secondary packaging, Dash recalled encountering inefficiencies as early as 2017 due to the industry’s reluctance to embrace new technologies. “Many in the industry hesitate to adopt new technologies due to fear of risks,” he explains, noting a prevalent mentality of “if it’s working, let it run.” He advocated for a shift in this mindset, arguing that “a little risk-taking can lead to significant advancements.”

To boost overall efficiency, Dash stressed the importance of minimising maintenance downtime and compressor-related costs. He explains that in bioequivalence (BQ) machines, semi-automatic setups experienced delays linked to embossing and perforation challenges. Fortunately, new solutions such as universal perforation tools can enhance efficiency by “30% to 55%” without necessitating major changes.

Dash has also collaborated with vendors to identify solutions for specific challenges, including the use of temperature sensors for embossing to eliminate light embossing issues. He firmly believes that implementing these universal tools can resolve many minor disruptions effectively.

He also highlighted the necessity of “line balancing.” Simply increasing the speed of counting and filling machines does not guarantee overall efficiency; it’s crucial to ensure that all components of the production line are synchronised. “If we enhance the speed of one machine, we must ensure subsequent machines can keep up,” Dash advised, adding that initiatives like track and trace may introduce slight slowdowns due to necessary coding, scanning and other processes.

Ultimately, Dash emphasises that “the key to increasing efficiency lies in a holistic approach,” where every element of the process is evaluated and optimised. Managing his responsibilities to minimise disruptions, he reflects on the interconnectedness of conveyors in bottle lines. He further ponders the evolution of camera technology, emphasising the importance of selecting the right tool for the specific objectives at hand.

IoT and sustainability: A balancing act

As sustainability becomes a focal point for consumers and regulators alike, the packaging industry is grappling with how to incorporate sustainable practices without compromising efficiency.

Nair elaborates on a significant hurdle faced by the industry – the government mandate to incorporate post-consumer recycled (PCR) material into our products. He noted that resistance emerged from R&D teams, particularly in rigid packaging. “The R&D team expressed concerns over the quality and specifications of PCR, especially in applications where packaging directly contacts products. We were advised to conduct compatibility studies for every product," Nair informs. He describes this process as a "mammoth task" that demands considerable time and effort, complicating compliance with governmental timelines.

However, Nair highlighted the role of existing technology in addressing this challenge. Leveraging multi-layer technology in their products enabled the incorporation of PCR into the middle layer, achieving an impressive "40 to 50% PCR" depending on specific components and designs. This innovation facilitated the market introduction of PCR products without the extensive compatibility studies initially deemed necessary.

In another example, Nair pointed out the intricacies involved in operating PPE films on form, fill, and seal machinery. He remarked, "The dynamics change," necessitating adjustments in settings and temperatures. Yet, he remained optimistic, seeing "indigenous capabilities" on the rise, with local developers creating machinery tailored for novel structures. He added, "There are manufacturers who can retrofit your existing lines," thereby enhancing their adaptability to new requirements. Nair stated, "Technology has helped us out" in meeting sustainability goals.

Sridhar showcased two innovative packaging technologies that are making waves. He described Plum as a brand that is pushing boundaries. One significant advancement he cited was 3D digital printing, a process many recognise. He highlights the transition from the convention of producing bottles to digital printing, emphasising its efficiency in minimising waste and reducing inventory costs. "This form of manufacturing not only reduces inventory costs but also ensures virtually zero downtime," he explained, pointing out the seamless integration of printing and filling processes.

Sridhar also shared an exciting innovation from Kao, mentioning a film bottle that incorporates air into its outer rim. "This design is ridiculous in a positive sense for its simplicity and efficiency," he remarks, illustrating how it creates a refillable solution. He detailed the three-layer laminate structure, stating, "The outer rim is air-infused, giving stability to the pouch or bottle shape." Notably, he concluded, this technology enables "easy dispensing through a pump attached to the inner film."

It therefore, becomes apparent that advancements in packaging technology, driven by IoT and other innovations, are key to harmonising sustainability with efficiency in the industry.

Shekhar built on what Sridhar mentioned. The transition from printing to digital tools is significant. Digital tools enhance consumer engagement by utilising devices like smartphones and tablets. This allows for easy scanning of digital content, whether through QR codes or barcodes on the labels.

Shekhar emphasised that this not only provides more comprehensive product information but also ensures the authenticity of the product in the marketplace. “Consumers will be able to verify if a product originates from the right manufacturer, which increases trust and can positively impact demand. This aspect of sustainability is crucial, as it empowers manufacturers to better connect with the market and engage consumers effectively.”

Challenges and opportunities in the packaging industry

As the panel drew to a close, the conversation shifted to the broader challenges and opportunities facing the packaging industry. The rise of e-commerce, changing consumer preferences, and evolving regulatory landscapes are all factors that impact how manufacturers approach packaging solutions.

With the increasing demand for online shopping, companies must adapt their packaging solutions to meet the needs of consumers who prioritise convenience and sustainability.

"Packaging is becoming an extension of the product itself," Wankhede notes. Consumers expect packaging to be not only functional but also environmentally friendly. "If a product arrives in excessive packaging, it can lead to negative perceptions of the brand," he warned, stressing the importance of aligning packaging strategies with consumer expectations.

The regulatory landscape is another critical consideration for packaging manufacturers. As governments implement stricter regulations surrounding sustainability and product safety, companies must navigate these complexities while maintaining operational efficiency.

Nair highlights the need for manufacturers to stay abreast of evolving regulations. "Compliance is not optional; it's a necessity," he asserts. Companies that fail to adapt risk facing penalties and reputational damage.

The panellists agree that collaboration with industry stakeholders, including regulatory bodies, is vital for ensuring compliance. "We must engage in discussions with regulators to understand their expectations and align our practices accordingly," Dash emphasised, highlighting the importance of proactive communication.

Looking ahead: the future of packaging

As the panel wrapped up, the discussion turned to the future of packaging. The consensus among the panellists was that innovation will continue to drive the industry forward, with a focus on sustainability, efficiency, and consumer engagement.

The panellists collectively emphasised the need for a culture of innovation within organisations. "We must foster an environment where employees feel empowered to experiment and propose new ideas," Nair states. By encouraging creativity and risk-taking, companies can unlock new growth opportunities.

Dash added, "Leaders must demonstrate their commitment to innovation by supporting initiatives that challenge the status quo," he emphasises. This commitment can inspire employees to embrace change and contribute to the organisation's long-term success.

The panellists express optimism about the potential of emerging technologies to reshape the packaging landscape. From advancements in AI and IoT to innovations in materials science, the future holds immense possibilities for enhancing efficiency and sustainability.