Growth doesn't have to mean uncontrolled complexity. According to PMMI's From Complexity to Capability white paper, the dominant message from packaging and processing executives is to start small, preserve options, and build confidence before fully automating.
When asked how to balance people and technology while scaling, 57% of leaders chose "start small, go slowly, and keep contingency plans." “Operator training, startup support, and front-end exposure” followed at 39%, with “stabilizing the process before automating” at 34%. The pattern points to a clear preference for execution discipline over speed.
Leaders also drew a line between scaling demand and scaling a system. "You're not scaling a machine. You have to scale the system," one participant says.
Floor space, buffers, sanitation, line interaction, material readiness, and workforce capability all determine whether added capacity produces real output. In that context, semi-automatic systems can be the right bridge when a new product or format still carries market uncertainty, and a scalable architecture with a credible expansion path can outperform peak automation locked in too early.
Uncertainty reinforces the case for caution. "The forecast is always wrong. You just don't know which direction and how far off," a participant says.
When asked what balancing cost and growth requires, 79% pointed to “balancing people and technology resources,” and 58% to “better use of data”—far ahead of “enhanced third-party digital/data services” (19%). This further signals that leaders increasingly view scaling as a whole-system issue rather than a standalone automation purchase.
Respondents also rejected treating scaling as a one-time equipment purchase. Partnership stood out as a clear lever for technical performance
The largest share of respondents wanted “frequent partnership meetings and executive alignment” (48%), followed by a “forward-looking partnership with OEM visibility into future needs” (41%).
Several participants argued that startup support belongs in the capital case and not as an afterthought. Many of the hardest OEE losses surface after handover, according to the white paper, when equipment is technically accepted, but the operating system around it is not yet stable.
For OEMs and suppliers, the opportunity lies in offering phased automation pathways, staying engaged through startup stabilization, and helping customers leave room to grow.
"Start small, scale with confidence ... leave space in there so you can automate in the future," a participant says.
SOURCE: 2026 From Complexity to Capability: Integrating Systems, People, and Partnerships for Future-Ready Packaging Operations
For more insights from PMMI's Business Intelligence team, find reports, including From Complexity to Capability, Building an AI Advantage in Packaging Equipment, and Trends and Challenges in Pharmaceutical Manufacturing at https://www.pmmi.org/business-intelligence.
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