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Smart Automation End of Line – Part 1: Is the Finishing Line the Final Frontier?

Picture of Mathieu Tremblay Mathieu Tremblay : November 5, 2025

Maximize Folder-Gluer Productivity Problems and Solutions Peripheral Equipment automation

Some directors dream of autonomous automation. The inherent complexity of the finishing department makes this goal unrealistic. Automation always comes at the cost of flexibility and versatility, and on a folder-gluer flexibility and versatility is often the name of the game.

Unlike printing and die-cutting, which are largely automated, the end-of-line in the finishing department is still highly manual. And it’s also the most complex to automate. Why is that?

In folding carton packaging, even minor product variations matter: blank thickness, humidity, storage time—all affect how the product behaves on the folder-gluer. This is why finishing-line work is still a craft, and why AI won’t be replacing folder-gluer operators any time soon.

On a printer or die-cutter, a sheet is a sheet. It comes in a predictable, consistent size. It flows through the process the same every time. But once the blank gets to the folder-gluer, variability explodes. Each box type is processed differently and each presents its own challenges.

A production manager analyzing a box near a folder-gluer

The work done in the finishing department is still a craft.

Historically, we’ve dealt with this variability with human intervention. Humans are adaptive and flexible — that’s their strength. But in the current labor context, those job positions are becoming harder than ever to fill. People aren't as eager to do physically demanding work. Additionally, humans have natural speed limitations, which cap the capacity on our line. So, there are critical reasons to automate the finishing department and specifically the end-of-line to reduce heavy lifting!

Human dexterity facilitates quick adaptation to changing product types and packing configurations.

SMART Automation

What is smart automation? Smart automation rarely means a totally autonomous production. The right level of automation fits your product mix and ROI goals. For some finishing lines a semi-automatic packer is the right solution...for others an automatic packer is a better fit. After integration of an automatic packer, additional automated machines can be incorporated until your line is fully automated.

In packaging and manufacturing, the first step toward automation is identifying a manual task or series of tasks that can be accomplished by a machine. You start by pinpointing your biggest bottleneck. Figure out what’s limiting the speed in your process. Once you start automating, you realize one solved bottleneck reveals another and you solve the new speed limiting factor.

A small step toward automating often requires big changes and triggers further automation. At some point the finishing line process becomes so fast, that human powered visual quality control can’t keep up. You will need high-speed inspection systems synced to your folder-gluer.

Every new level of automation changes:

• Machine setup and changeover

• Crew roles and skill requirements

• Scheduling for people and products

• Quality control and process optimization

• KPIs and performance evaluation

Left: A woman lifts a heavy shipping case; Right: a palletizer robot lifts a shipping case;

Moving from manual tasks to automated processes isn’t a simple linear process.

Starting the Automation Journey

At this point in the discussion some teams start to feel overwhelmed. But don’t think of this as ‘a never-ending journey that you’re better off not starting’. Knowing the end game helps guide the process. With each step you get closer to smart automation. A smart automation approach prevents your journey from becoming an overly expensive domino effect. Ironically, the "less glamorous" finishing lines can present the best balance of investment and productivity. After analyzing hundreds of finishing lines four common scenarios emerge.

Common Levels of Automation:

Manual: Most tasks are accomplished by humans, only the folding and gluing is automated.
Semi-Automated: Some tasks are automated, others manual.
Automated: Humans remain involved, but machines do the heavy lifting.
Fully Automated: Fully automated, human presence only for setup and make-readies.

line drawings of 4 finishing lines: The first shows manual packing with 2 workers, Second line is Semi-Automated with one worker and a palletizer robot, third is automated with one worker, the forth is fully automated with no workers at the end of line.

Which level of automation is right for each of your finishing lines? In part 2 of this article series, we will take a deep dive into the levels of automation and show you how to identify the optimal solution for your finishing lines, but first let’s talk about...

BASIC PRINCIPLES of SMART Automation

Optimize Your Department

Standardize before you automate. Don’t automate chaos. M

This is where smart scheduling and product specialization on folder-gluers matter. AI isn't able to automate the physical tasks, at least not yet, but it can help with planning and scheduling. You don’t need to do every job on every folder-gluer. Use data to segment tasks and simplify changeovers. Data can help identify patterns so you can be agile and assign jobs to specialized lines and minimize setup times. For example, you could dedicate a folder-gluer to high-volume straight-line boxes with an automatic packer. Then, for the shorter runs and more complex products, have a semi-automatic modular packing station on a more flexible production line.

Master the Folder-Gluer Process

Automation introduces complexity. Poor management on the finishing line can erase the gains made earlier in printing or die-cutting. Printed, foiled, die-cut cartons can end up wasted if folder-gluer output isn't managed correctly. Raise speed without managing quality, and your waste rate increases. This is why it’s so important to master the folder-gluer process and optimize the entire workflow as you introduce automation.

MODULARITY

Smart automation is flexible & modular. Modular systems allow you to scale and adapt to changing needs. Your system and process can’t be static in an industry undergoing so much change. It allows you to create a tailored solution from available machines, often from several OEMs.

CONNECTIVITY

Integrate digitally. Connectivity allows various systems to talk to each other. Ensure your systems (ERP, MES, scheduling) can talk to your equipment. Collect data, measure performance, optimize schedules, set targets and improve continuously.

A fully connected solution allows packaging producers to leverage the data managed by various machines in the system. This is why we at IMPACK, like several other OEMs, have recently developed and released an all-new automation app.

Two men look at an HMI screen. One makes selections by pushing buttons on the screen.

Left: Frederic Boyadjian, P. Eng., Head of Automation at IMPACK, led his team in designing an innovative automation app with B&R’s Automation Studio to meet tomorrow’s needs.

Considerations for Successful Integration

Is your process optimized, standardized and digitized in general?
Are your people ready for change?
Have you aligned your strategy to find the perfect balance between flexibility and your throughput goals?
Are you measuring ROI based on real, broad metrics?

Summary

Our goal at IMPACK is to find new ways to do things and new ways to partner. After 20+ years of studying folder-gluer finishing lines, we’ve learned:

Full automation isn't always the end goal.
Semi-automation is often the smartest first step.
Success comes from alignment—not just equipment.

It’s time for a mindset change. Automation isn’t a magic pill that solves all our ills. There’s not one machine that solves everything. Automation is a process — not a product. Don't automate because you can. Automate because it solves a clear problem.

Automation is not the goal, it is a way of thinking. Automation is a way to increase capacity with the same number of staff and space. It’s a way to improve the working conditions of your team. It's the way to run, grow and optimize your business.