A Practical Guide to Entry, Mid & High-Level Packaging Automation Solutions
TL;DR
If you want to improve productivity, cut waste and control costs in 2026, packaging automation could be the answer.
- Entry-level automation offers quick wins with low investment.
- Mid-level automation boosts speed and flexibility as you grow.
- High-level automation delivers fully integrated, high-speed packing lines.
As costs rise and businesses are under pressure, unlocking savings will be important for many. Enter packaging automation. It could be the answer to cutting costs, reducing waste and improving your productivity!
While automation might seem like a big expense, it can be quite cost effective, with solutions available for every budget.
In this article, we’ll dive into an overview of packaging automation and what it offers, as well as highlighting types of automated packaging systems that offer entry-level, mid-level and top-level solutions.
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What is packaging automation?
Packaging automation is using machinery or equipment to complete part or all your packing processes, rather than doing it by hand.
Tasks automation can do for you include (but are not limited to):
- Assembling boxes
- Sealing boxes
- Dispensing tape
- Pallet wrapping
- Labelling
- Bagging
- Filling empty space in parcels (void filling)
- Moving parcels
Instead of relying fully on manual labour, packaging machinery improves speed, consistency and safety.
Why businesses are investing in automated packaging systems
Across the UK, businesses are facing a variety of challenging conditions. These include rising labour costs, pressures to improve productivity, supply chain disruptions and more stringent sustainability requirements. On top of this, customers expect more than ever before.
Automated packaging systems help tackle all these challenges.
Implementing packing automation can provide these advantages:
- Faster packing speeds
- Lower material waste
- Improved pack consistency
- Reduced damages / better protection
- Improved health and safety
- Overall cost reduction
- Carbon emissions savings
While you may think packaging machinery is costly, there are options for every budget and business size. The key is choosing the right level for your operation…
Entry-level packaging machinery
Beginner or entry-level packaging automation can often give you quick wins with minimal disruption and a budget-friendly price.
These options are ideal if you’re just starting your automation journey as they’re affordable, simple to install and don’t require major layout changes.
Typical entry-level automated packaging systems
- Gummed paper tape machines – these improve box sealing speed and reduce tape waste (our most popular model is the BP555).
- Friction welders – these are battery operated, handheld machines that seal plastic strapping and banding together. A simple, straightforward tool for securing heavy boxes where tape won’t work or securing pallets.
- Semi-automatic pallet wrappers – if you’re wrapping 15 or more pallets a day, you could benefit from a turntable pallet wrapping machine. They’re efficient and help you use less plastic film, while making sure loads are effectively contained.
Individual void fill machines – there are “plug and play” void fill machines available for a reasonable one-off cost. They can produce paper or air cushioning on demand, speeding up how easily you can protect your products.
Mid-Level Packaging Automation Options
If you’ve already implemented some entry level equipment and need a further boost, or have gone through a phase of growth, mid-level packaging machinery might be for you.
Balancing speed and flexibility these solutions increase throughput while managing higher volumes.
Typical mid-level packaging machinery
- Case erectors – these machines will consistently erect cardboard cartons. Mid-level machines usually work with one size case at a time, so suit a production line working with a controlled amount of SKU sizes
- Case sealers – these machines use glue or tape to seal boxes shut. The basic models work with one size carton or case at a time.
- Integrated void fill systems – integrated void fill systems can feed multiple pack areas at the same time, dispensing protective material into big bins ready for use, automatically replenishing them when running low.
- Strapping machines – a step up from friction welders, these can help you strap entire pallets or boxes automatically.
- Orbital wrappers or robot wrappers – for packing larger volumes of long items, loads you can’t rotate or floor-based wrapping.
High-Level Automation Solutions
High-level automation is designed for high-volume, high-speed environments where efficiency is critical. Time is often money and during peak demand automation can pay dividends by offsetting the need for temporary labour.
These are complete automated packaging systems that integrate multiple processes into one streamlined line. Machinery at this level is often designed to “right-size” packaging, minimising waste and maximising quality control.
Typical high-level packaging machinery
- Right-size carton systems and void reduction – these machines make boxes around your product, so it’s the right size every time. This reduces waste and optimises cubage for transport.
- Automatic random case sealers – these work like standard case sealers, using glue or tape, but will adapt to different size boxes, allowing you the flexibility to seal cartons for multiple SKUs.
- In-line void-fill systems – these systems automatically dispense protective material like air pillows or paper cushions into a box, only dispensing what is needed for the pack. They remove the element of overpacking while maintaining in-box product protection.
- Auto bagging systems – both horizontal and bagging systems can be used to improve efficiency. Horizontal bagging systems are often used in-line, whereas vertical baggers require some manual intervention.
- Conveyors and labelling systems – these systems enable you to move product through your warehouse and then label them for dispatch. Ideal if you’re working in a large space.
How to choose the right level of automation
Choosing the right solution depends on a variety of different factors, including:
- Your current packing volumes
- Labour availability
- Your product specifications
- Budget
- Space available
- Growth plans
- Sustainability goals
A step-by-step approach works best. Many companies start with entry-level packaging automation, then scale to mid or high-level systems as demand increases. (Our team can help you decide the best course of action, feel free to get in touch).
Frequently Asked Questions
Packaging automation uses machines to carry out packing tasks such as sealing, wrapping, filling and labelling. It improves speed, safety and consistency.
Not always. Entry-level packaging machinery can deliver strong returns without major capital investment. High-level systems cost more but provide larger productivity gains.
No. Most businesses use automated packaging systems to support their teams, not replace them. Staff can focus on quality control and higher-value tasks.
Many solutions provide return on investment within 12–24 months, depending on volume and labour savings. For larger systems, there can be ways to spread the cost too.
Yes. Many automation solutions help reduce waste and improve consistency. For example, right-sizing box, reducing void fill and optimising stretch wrap all help reduce material use and carbon impact.
Support automating your packing processes
In 2026, productivity and cost control are critical for UK businesses.
From simple packaging machinery upgrades to fully integrated automated packaging systems, the right solution can boost efficiency, cut waste, improve safety and help you cut overall costs.
If you’re ready to take smart, scalable steps that deliver measurable improvements get in touch with Macfarlane’s packaging experts today. We offer end-to-end automation from design and recommendation to supply of machinery, consumables and installation.