There are many exciting things happening in 2026 for the secondary packaging industry. As a whole, the industry is seeing a push toward sustainable packaging solutions driven by consumer demand and regulatory requirements. And food processors and co-packers/manufacturers are more interested in robotics than ever as they evaluate automation for secondary packaging to mitigate labor constraints, machine maintenance, and other pressures on their bottom line.
At BPA, we are helping our customers along the way with new machines and innovations that support their goals for 2026..
Things are moving fast, and to better understand what’s shaping decisions on the factory floor, we asked our industry experts to unpack what’s driving investment and automation this year. Topics discussed include the following:
The grocery store aisle has a lot of competition for shelf space and consumer attention. Retail-ready packaging helps retailers sell and stock their products. Shredded cheese is one sector where we have seen retail-ready packaging shine, but the format can be applied to a wide variety of foods and snacks that require easy handling and maximum exposure.
Retailers are looking for retail-ready presentations that offer clear branding, are easy to open, and improve the appearance of the shelf. They should also be sized to fit the requirements requested by the retailer and offer significant protection during transport to prevent waste.
At BPA, we listened to your requests and developed the Easy-D retail-ready case. The Easy-D uses a pre-cut front panel that wraps around the corners to give it a premium look on the shelf. It features a higher back wall, providing better support for flexible pouches or light containers. The Easy D’s wraparound design ensures easy loading and reduced packaging to keep your costs down.
Additionally, more manufacturing companies are abandoning secondary plastic bags for variety snacks. “Bag-in-bag” formats are being replaced by recyclable variety pack cartons, and these applications can be automated. New systems can utilize multi-feeder lines to drop specific flavor ratios into a single case, eliminating the need for manual collation.
We have previously discussed various variety pack automation methods, including a drop chute system, robotics, and the traditional case packer. Here is an example of a three-flavor gravity variety pack case packing system that collates and drops bags of chips into the cases below.
Variety pack production requires secondary packaging systems to be flexible and fast. By adding automation, food producers and co-packers/manufacturers can eliminate labor-intensive manual packing to ensure perfect flavor counts every time. This helps meet customer demand while slashing costs and updating packaging to give producers a competitive edge in a crowded market.
One regulatory area drawing increased attention is Extended Producer Responsibility (EPR) legislation in California, Oregon, Colorado, and Maine. These laws impose strict reporting requirements on consumer packaged goods (CPG) companies, requiring them to track and report the precise weight of all plastic and corrugated packaging shipped into the state.
As a result, manufacturers may pursue new secondary packaging initiatives, including the following:
Recently, our sales engineers have seen more interest in sophisticated robotics to enhance companies’ secondary packaging operations. Advancements in vision systems, end-of-arm tooling, and controls have also reduced the perceived risk of robotics, making them more approachable and easier to integrate than in the past.
That said, robotics are not the right fit for every operation. Some of our customers favor semi-automatic or traditional case packing systems due to lower upfront investment, simpler maintenance, and limited access to technical talent. For these operations, reliability and ease of support often outweigh the need for maximum flexibility.
Manufacturers tend to fall into three tiers when it comes to secondary packaging preferences:
BPA offers solutions in all three tiers to support our customers’ needs. Our sales engineers can help you determine the best system to handle your production goals.
Operational strategy is frequently dictated by a strict 24-month rule for capital expenditures. However, evaluating automation solely through a two-year payback window often ignores the broader Total Cost of Ownership (TCO) over the equipment's entire lifecycle.
Beyond the initial sticker price, fiscal viability must account for long-term maintenance, energy efficiency, and the escalating costs of the human factor. With chronic labor shortages and shifting plant floor cultures, the cost of inaction often outweighs the amortized cost of the machine.
Manufacturing leaders must look past immediate ROI to see how automation stabilizes operational expenses over an extended period. Automation decisions based on TCO can lead to lifetime cost reductions of as much as 30%. Here are some of the ways ROI and TCO are impacting purchasing decisions for secondary packaging lines:
With more food producers and co-packers/manufacturers interested in robotics, retail-ready packaging, and other trends, you will need a partner who will help you find the best machine solution to enhance your secondary packaging operations. BPA offers advanced automation backed by industry expertise to narrow your search and ensure alignment with your needs and budget.
Stay tuned for future announcements about machine demonstrations at a trade show near you. For more information on our secondary packaging solutions for your sector or to request a line audit, contact us today. The possibilities for 2026 are endless.