Our team recently returned from Pack Expo in Las Vegas, one of the largest gatherings for packaging, processing, and automation solutions. With so many exhibitors and technologies on display, it was an opportunity to connect with partners, explore emerging innovations, and gather insights into where the industry is heading.

Here are some highlights from Daniel Caceres, Vice President of Packaging Sales; Brett Simpson, Strategic Sourcing Analyst; and Jordan Sellers, Packaging Account Manager - who represented our team at the event.

Automation Innovations

Automation continues to be a central focus for the industry. Thanks to industry advancements, more compact and cost-effective basic automation options are now available, making automation accessible to skeptical or budget-conscious customers. making automation more accessible for smaller operations. Semi-automatic solutions also offer a cost-effective alternative for load wrapping while while enhancing operational efficiency and reducing manual effort.

Advanced labeling and print-and-apply systems were a highlight, designed for efficiency in high-volume or limited-space environments. Customizable automation solutions—spanning heat sealing, conveyance, and collaborative robotics—allow companies to maximize space, ensure consistent output, and achieve operational scalability while reducing costs.

AI integration is increasingly common in automation equipment, driving improvements across multiple dimensions. AI-powered systems can adjust operational parameters in real time to optimize throughput, reduce material waste, and minimize downtime. Predictive maintenance powered by AI can anticipate equipment failures before they occur, reducing unplanned interruptions and extending machine life. AI also enables smarter quality control by detecting defects or inconsistencies that would be difficult to catch manually, improving product consistency and reducing scrap.

In addition, AI is helping manufacturers simulate workflows and production scenarios to identify efficiency gains and cost-saving opportunities before making physical changes on the line. Combined with automation, these capabilities make packaging processes more intelligent, adaptable, and sustainable.

Material Innovations

One of the strongest takeaways from SPC Advance is that sustainability continues to be one of the most relevant and forward-looking topics in packaging. The conversation has moved well beyond materials alone and now encompasses a wide range of strategies: process optimization, right-sizing, reusable and recyclable components, lightweighting, waste reduction, energy-efficient automation, circular economy initiatives, and smarter logistics that reduce carbon emissions.

Innovations are also expanding the options available to brands. Companies are exploring biodegradable films, compostable packaging, refill systems, and digital tools that track and reduce environmental impact. In the stretch film category, for example, recycled-content films are now available with up to 30% post-consumer recycled material—delivering performance comparable to traditional films while supporting circular economy goals. These advancements allow companies to meet sustainability commitments without sacrificing quality or load stability.

Alternatives to traditional foam products are also gaining traction, offering both environmental benefits and cost savings. Fully recyclable or biodegradable materials are now replacing foam coolers, helping reduce shipping volume and warehouse storage requirements. Because these solutions can ship flat, they lower freight costs and drive operational efficiencies across the supply chain.

The combination of material innovation and automation demonstrates how sustainability, efficiency, and cost-effectiveness can work together. New packaging solutions are designed not only to reduce environmental impact but also to optimize labor, storage, and transportation costs.

Looking Ahead

With 2,300 exhibitors showcasing the latest packaging and processing innovations, PACK EXPO Las Vegas 2025 delivered a lot of great innovation. The event provided a valuable opportunity to see emerging trends, connect with partners, and explore innovations in automation and sustainable materials.

Looking ahead, PACK EXPO International 2026 in Chicago promises to be even bigger and more dynamic. With attendees from over 40 vertical industries and more than 2,600 exhibitors, the possibilities for networking, innovation, and new business opportunities are endless. Our team is excited to continue exploring trends, discovering breakthrough technologies, and bringing these insights back to deliver value for our customers.