Advancing Food Manufacturing Through Digital Transformation
Every food and beverage manufacturing company consistently seeks to improve efficiency on packaging lines. Thankfully, a new era is dawning: digitalized tools are helping processors meet their goals more rapidly, according to PMMI, The Association for Packaging and Processing Technologies. Some of the tools in the digital transformation journey include predictive maintenance (PdM), digital troubleshooting products, machine learning-based vision systems, and of course, artificial intelligence (AI) systems.
PMMI’s 2026 report, “Building an AI Advantage in Packaging Equipment,” states that major obstacles in food and beverage plants’ quest for efficiency are a lack of visibility across sites and inconsistent reporting that slows operations and increases downtime. An AI-powered connected worker platform that addresses these challenges by digitizing frontline workflows and using AI-driven insights can improve safety, quality and productivity.
Another thing we are hearing from companies is that AI-powered machine vision enhances the quality of detection and provides simulations to detect smaller irregularities than ever before. This level of accuracy is increasingly important due to rising consumer expectations and regulatory pressures demanding zero-defect packaging. AI-driven machine vision not only reduces reliance on manual inspection, but it also mitigates labor shortages and supports compliance with sustainability and safety standards.
Therefore, it comes as no surprise that, according to an earlier PMMI report, “The AI Advantage in Equipment,” machine vision ranked among the top five AI applications, delivering measurable impact in packaging, alongside PdM and digital twins. Since that report was released in 2024, machine vision accuracy has improved significantly. In fact, participants in PMMI’s 2026 report indicated that defect detection rates now exceed 99%, while false rejection rates have dropped by up to 50%, reducing waste and improving throughput. These advancements demonstrate why machine vision has been a strategic priority for packaging companies since at least 2024.
Advanced Tools Add More Value
As digital data grows exponentially across business functions, manual management becomes even more inefficient and error-prone. AI-driven tools address the difficulties associated with manual management by automatically categorizing documents, eliminating redundancies and creating relational structures that support advanced analytics. AI systems streamline search times, improve reporting accuracy and enable faster, data-driven decision-making. For end users, this means critical information can be located quickly without adding operational complexity.
PdM and digital troubleshooting tools also are gaining more traction, although adoption varies depending on the customer’s comfort level with data sharing and remote diagnostics. In PMMI’s State of the Industry 2025 study, one interviewee described the introduction of a machine learning-based vision system to detect defective products more quickly and accurately. While the system struggled with reliability, only a traditional sensor backup was required to ensure consistent results.
Start Your Digital Transformation with a Roadmap
Sometimes, there are misconceptions about digital transformation, such as the belief that it’s a massive undertaking that must be done all at once. In reality, companies can do it in steps that provide significant value at every level.
Effective projects usually start small with defined business cases. That way, companies can prove return on investment, then scale up. Momentum is built by achieving successes delivering quantifiable results.
The Digital Transformation Roadmap, a work product released by PMMI’s OpX Leadership Network, serves as a guide to help consumer packaged goods companies, original equipment manufacturers and system integrators fully realize the value of data trapped within multiple operational assets and move into an era of excellence in digital operations.
In short, the work product guides businesses on where to begin their journey and how to tailor the transformation process. It also helps businesses assess their current level of automation maturity and readiness for embarking on the digital transformation process.
Highlights of the Digital Transformation Roadmap include:
- The benefits of digitalization
- Starting the digital transformation journey
- Putting it all together
- Seeing real-world results
PACK EXPO International 2026 offers an efficient way to find solutions, explore innovations and move automation and digital transformation projects in the right direction.
Show attendees can explore innovations for more than 40 vertical industries, broadening their perspective beyond their own market and gaining insight into how other sectors are addressing similar challenges.
Held only once every two years, PACK EXPO International is a can’t-miss opportunity for packaging and processing professionals. Whether you’re solving immediate challenges or future-proofing your operations, PACK EXPO International 2026 (Oct. 18–21 at Chicago’s McCormick Place) is the best place to start.
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