Supporting the Workforce with Automated Packaging
Fast-paced and evolving, the packaging industry relies heavily on its workforce to meet growing demand. During seasonal peaks, where output needs to be accelerated, business typically require additional workers to take full advantage of these opportunities.
Today’s worldwide recruitment challenges are very real, driven by a host of factors, from rising labour costs to high staff turnover and these are felt more keenly on the physically demanding shop floor than anywhere else. As a result, businesses of all sizes are exploring ways to support and reduce the pressure on existing employees, in a bid to raise morale and improve worker retention rates.
Automation offers a powerful solution, ticking vital boxes to help create a more sustainable approach to the workforce strategy. With more than a century of experience, we’ve seen this happen first hand. In this article, we’re here to highlight how the introduction of automated packaging can help to reduce labour pressures, enhance efficiency and comprehensively support your workers.
Labour shortages and demand fluctuation
Across the manufacturing industry, there is a growing concern about the difficulties faced in the labour market. According to global expectations, by 2030 these could represent around 85 million skilled workers, potentially resulting in losses of up to $8.5 trillion USD in unrealised global annual revenues. In the UK alone, the manufacturing sector reported 61,000 job vacancies (September 2024 – Barclays Corporate) up from 24,000 in 2020.
Shortages are driven by key factors, such as fewer young workers entering the industry to replace skilled and experienced staff, a surprising 20% of whom, according to industry figures, will retire by 2026, exacerbating the existing skills gap across the manufacturing sector. Let’s look at some other key areas:
Rising labour costs
The rising cost of labour and benefits makes hiring short-term staff more problematic and less flexible for packaging companies. In the UK, the National Living Wage rose to £12.21 this year (April 2025) for workers over 21 alongside a National Insurance increase from 13.8% to 15%. With the lower earnings threshold lowered from £9,100 to £5,000, this spells higher costs for businesses and particularly impacts those that rely on seasonal or part-time workers.
If we take a look at the real cumulative financial impact for a business employing ten minimum wage workers, in real terms this could equate to an additional annual cost of over £26,000 – just in wage and NIC rises.
Seasonal influences
Demand fluctuates in certain sectors, and some experience seasonal influences, where output needs to increase for sometimes short periods of time. For instance, the toy manufacturing sector ramps up production in the run up to Christmas, when approximately 50% of toy sales occur. Garden furniture manufacturers experience peak demand during the spring and summer months. To maintain consistent output and avoid overproduction during off-peak times, meet deadlines and stay competitive, now is the time to tackle these challenges head-on and ensure packaging lines can operate flexibly.
How automated packaging supports the workforce and the business
To improve worker retention and increase morale, automation can become a powerful tool, not designed to replace staff, but to support them fully and reduce the pressure. More than that, packaging businesses are also realising the wider benefits of implementing the right technology in the right places:
Reducing the reliance on manual labour – automation can minimise the need for a larger labour force by handling the most repetitive, time-consuming processes, allowing businesses to operate with leaner teams and maintain or even increase output. Companies that have embraced automation have reported a 15% decrease in employee turnover within 12 months, which translates into substantial recruitment and training costs. Overall, some businesses could reduce their operating costs by up to an impressive 70% over the long term, helping to increase the short-term ROI significantly.
Enhancing productivity and job satisfaction – studies indicate that machines can complement the workforce and increase productivity by up to 24% over a five-year period. By giving workers the opportunity to focus on more skilled, value-added roles, such as quality control and strategic optimisation of the packaging process, they feel safer, more valued and less physically strained at the end of a shift, helping to increase staff retention.
Seamlessly meeting compliance – compliance is a core requirement in many packaging sectors. Some are heavily regulated, such as pharmaceuticals, tissue, hygiene, and food. Automating compliance is simplified with the right technology and reduces the training required for this vital element, especially for seasonal staff.
Ensuring consistent, high-quality output – human error is inevitable in a manual production line, but the resulting defects, inconsistencies and waste is negated with automated packaging. Whether semi- or fully-automated, machinery ensures precision – every single time – and staff can instead focus on quality control and distribution.
Boosting efficiency and production speed – automated packaging machines operate at high speeds, significantly increasing capacity and allowing companies to meet consumer demand with fewer skilled workers. This creates the flexibility and more importantly, the scalability of operations with none of the traditional short-term staffing challenges.
Improving shop floor safety – packaging lines expose workers to repetitive motion, heavy lifting and potential hazards every day. When machines manage core processes, businesses can help to minimise workplace injuries and fatigue-related mistakes, fostering a much safer and healthier work environment.
A practical, sustainable approach
In today’s unpredictable labour market, automated packaging solutions bring a practical and sustainable solution. While some fear that automation will lead to job losses, the reality is far more nuanced, as machinery can actually improve operations and support existing, skilled staff in more strategic roles.
By focussing on workforce development, upskilling and retraining, rather than displacement, companies can create a more resilient and future-ready bank of loyal staff with better working conditions overall.
Can we help you to support your workforce?
At Jacob White, we know that many packaging lines are struggling with workforce limitations. Investing in automation is a necessity for long term success and gaining a competitive advantage.
If you’re ready to explore automation in your production line, we’re here to help you achieve your goals, improve ROI and support your staff. With thoughtful introduction of automation, you can address not only labour challenges but also realise tangible business benefits and significant cost reductions.
Contact us today to find out more about how our machines can transform your operations and give your workforce the vital support they need.
