By: ICN Bureau
Last updated : May 19, 2025 8:17 am
Automated packaging is delivering high ROI through increased efficiency, reduced waste, and lower operational costs
As the chemical industry embraces Industry 4.0, automated packaging is emerging as a game-changer by boosting speed, safety, and precision on the production floor. By integrating robotics, smart sensors, and data-driven systems, manufacturers are redefining how chemicals are packed, handled, and delivered.
Leading industry experts discussed the latest scenario at the second session, 'Automated Packaging: The Future of Chemical Manufacturing’ at the maiden edition of Chem & Petchem Conference 2025 organized by the Indian Chemical News on May 07-10, 2025 at Baruch in Gujarat.
The session was moderated by Murari Mohan Jha, Editor, Indian Chemical News.
"Automated packaging system in chemical industry has registered an increase because of a lot benefits such as efficiency, safety, high throughput, quality improvement and collection of data for analysis. In terms of safety aspects, if we try to pack the hazardous chemicals through manual operations, it creates a lot of hazards for human beings. Comparatively the automated system reduces the hazards and also good for environment as it is a major factor these days. Even the quality control is more robust when automated as compared to manual system where there is a huge room for errors. Without ROI, no project can go ahead and its implementation depends on the output. Automation helps in cut down the product loss and such savings help in creating a fair ROI. Any ROI of 30-50% is good for the project to be implemented. To avoid the customer complaints in terms of lesser weight of material as day by day chemical production is increasing and to control it we need the automation,” said Animesh Dhar, AVP - Site Head (Jhagadia), Privi Speciality Chemicals.
“We had a semi-automated packaging system at old plant at Dahej manufacturing site and the site has grown multi fold in last three decades with fully automated system having auto-storage and retrieval system and highest form of automation. As a major group, we have continuously given highest priority to digitalisation including packaging system and integration of data through data collection at ground level through sensors. The integration with ware house management and ERP. Another aspect is business continuity and we experienced the disruptions during Covid. Decision of automation depends on high throughput and transportation requirement of customers. Whenever we are going for automation, there is a need for integration of existing system or complete takeover depending on the requirement of the customers. Type of load or type of product also determines the number of steps needed to be taken for the automation," said Chandrakant Patel, Senior General Manager & Head - Warehousing, RIL.
“Industry is more concerned about the infrastructure and adoption in new spaces. Other challenges are skill development and lack of acceptability among employees for new technologies. If you choose any of the sequential operation and there will be any temporary malfunction, then if will cause disruption of operations thus affecting productivity. Another challenge is the high operational cost and thus requiring more investment initially. The packaging industry is evolving fast and maintenance of the equipment is an issue. Data safety and security is a challenge as the privacy is a concern but we take this as an opportunity to address such issues. We are having 28 manufacturing sites globally. In India, we We have started the manual operation where the loading of bags was done with weight adjustment manually followed by sealing and stiching. These processes caused both environmental issues as well as hectic schedule due to passing of bags from one conyevor belt to the other. When we switched on to automated system, we require just two labours. From just 14 metric tonnes of design capacity we have now 35 metric tonnes capacity, also reducing the environmental hazards by shifting to a closed door space instead of an open ground. Bringing in automation has helped us to increase efficiency, reduce cost and improve productivity,” said Kisna Kadu, Production Manager, SNF Flopam.
“Packaging in chemical industry is undergoing a significant transformation in terms of adoption of full automated systems driven by higher efficiency, consistent quality, safety and traceability. At PremierTech, we are seeing a lot of upward trends among our customers, especially in agrochemicals, pesticides, speciality chemicals and polymer industry towards adopting solutions such as robotic open mouth bagging system, robotic palletizer, jumbo bagging system and all. These days a customer is no longer just looking at machinery but integrated intelligent system that can deliver consistent output, reduce manpower dependency and minimise the down time. Our advanced technology solutions such as advanced backfacing, servo control dosing, remote monitoring are helping the customers to achieve not just better quality but safety and clean environment which is the need of the hour for chemical industry currently. In the recent years, automated systems have seen remarkable innovations driven by industry 4.0, sustainability and process optimization. Our company offers many such solutions to reduce manpower dependency and that will be independent work. As a result they will get better productivity and overall return on their investment,” said Prashant Mishra, National Sales Manager, PremierTech Systems & Automation.
Gujarat Chem & Petchem Conference 2025 witnessed massive attendance by leading industry experts and stakeholders across Gujarat and India. The 2-day event witnessed over 75 speakers discussing the latest trends of the chemical industry through panel discussions and presentations.
The conference was supported by Academia partner - Somaiya Vidyavihar University; Platinum partners - PremierTech Systems & Automation, ABB India, and Netradyne; Gold partners - Tvarit GmbH (Germany), SNF Flopam India, Alleima India, AMETEK Land Instruments International, BEIL, UPL University of Sustainable Technology, Forbes Marshall, Utthunga Technology, Syinfotech, Servilink Systems, Graphite India, Thermax, Gem Machinery & Allied Industries and Thermax; Associate partners - Diyani Automation, Flaminia Ecarb India, LAPP India, Goodrich Gasket, and GD Waldner; Industry Association partners - Gujarat Chemical Association (GCA), Jhagadia Industries Association (JIA), Dahej Industries Association (DIA) and Alkali Manufacturers Association of India (AMAI).