Transforming Snack Manufacturing: The Rise of Robotic Automation and AI in Secondary Packaging

In recent years, the world of snack manufacturing has been witnessing a profound transformation, driven by the accelerated adoption of robotic automation and artificial intelligence (AI) technologies. This trend has been fueled by a combination of technical advancements and the pressing challenges presented by the COVID-19 pandemic. In this article, we delve into how these innovations are reshaping secondary packaging and end-of-line operations within the snack manufacturing industry.

Several snack manufacturers (BPA customers) have already embraced these technologies with notable success, for example by using algorithms and robotics with higher output and a smaller footprint and by using visual inspection with learning algorithms that lead to fewer recalls and higher product quality (read more about this further down in the article).

The Snack Industry Landscape

The snack manufacturing sector is thriving, with consumers embracing snacking as an integral part of their daily routines. Whether it's chips, nuts, crackers, or healthier alternatives, snacks have become a staple in households worldwide. This increased demand (in SKU’s and numbers) presents both opportunities and challenges for snack manufacturers.

Meeting the growing demand while maintaining product quality and efficiency can be a tall order. The industry faced further hurdles with the onset of the COVID-19 pandemic, which disrupted supply chains and exposed vulnerabilities in manual labor-dependent processes.

The Role of Automation

To navigate these challenges and keep up with the demand, snack manufacturers turned to automation technologies. Robotics and AI have become indispensable tools in streamlining secondary packaging and end-of-line operations.

Robotic arms, equipped with advanced sensors and control systems, are now responsible for tasks such as picking and placing snacks into packaging, sealing containers, and stacking finished products onto pallets. These machines work tirelessly, ensuring precision and consistency, even in high-speed production environments.

Key Benefits of Automation in Snack Manufacturing:

The adoption of automation in snack manufacturing brings several benefits to the table:

Increased Efficiency: Automation accelerates packaging processes, reducing labor costs and minimizing errors. Snack manufacturers can now meet surges in demand without compromising efficiency.

Enhanced Quality Control: Automation systems employ cutting-edge technology to guarantee consistent product quality. From inspecting individual snacks for imperfections to verifying packaging integrity, automation systems leave no room for errors.

Scalability: One of the standout advantages of automated systems is their scalability. Manufacturers can easily adjust production capacity to match fluctuating market demands, providing flexibility that was once unimaginable.

Adaptability: Modern automation systems are incredibly flexible, accommodating various packaging formats and sizes. This adaptability enables snack manufacturers to diversify their product offerings without major retooling.

Practical Examples from BluePrint Automation

Several snack manufacturers (BPA customers) have already embraced these technologies with notable success. Companies that have integrated robotic automation and AI report significant improvements in efficiency, cost savings and product quality. For example, an Australian snack food manufacturer has used algorithms and robotics for a case packer with a higher output and a smaller footprint. This increased efficiency from 98% to 99.8%, resulting in less food waste. 1.8% may not seem like much, but that means approximately 7 bags less waste per minute, which is significant for 24/7 production. At a dairy manufacturer, visual inspection is automated with cameras that check the quality of products using learning algorithms. This leads to fewer recalls and higher product quality. By applying smart algorithms in a robotic packaging machine, wear and damage can be detected early, preventing unplanned downtime, leading to less product loss and significant cost savings.

Challenges and Considerations

While the benefits of automation and AI in snack manufacturing are clear, there are challenges to consider. Initial investment costs, including the purchase of automation equipment and staff training, can be substantial. However, companies often find that the long-term benefits far outweigh these upfront expenses.

Future Trends

Looking ahead, we anticipate even more transformative trends in snack manufacturing automation. Collaborative robots (cobots) are gaining traction, working alongside human employees to enhance productivity and safety. Predictive maintenance powered by AI is becoming the norm, reducing unplanned downtime and increasing overall efficiency.


In conclusion, the snack manufacturing industry is in the midst of a technological revolution, driven by the adoption of robotic automation and AI. These innovations are redefining the way secondary packaging and end-of-line operations are carried out, allowing manufacturers to meet growing demands, ensure product quality, and stay ahead in a competitive market.

As consumer preferences continue to evolve, and as technology continues to advance, snack manufacturers that embrace automation and AI will be well-positioned to thrive in an ever-changing landscape. The future of snacks is not just in the snacks themselves but also in the technology that brings them to our tables efficiently and with the highest quality.

Back to the overview