FEATURES OF DIGITAL TRANSFORMATION PROCESSES IN PACKAGING PRODUCTION

ABSTRACT

The article is devoted to the study of the features of digital transformation processes in packaging production. It reveals the trends of growth and structural diversification of the industry, identifies the stages of the production cycle (research, production, management, and logistics), and outlines the main directions of their digitalization. A conceptual model of digital transformation is presented, assuming a systemic and interconnected use of technologies aimed at increasing the efficiency of production processes. The principles of effective organization of packaging production are defined (flow continuity, rationality, adaptability, integration of quality and environmental management systems, innovation). Conclusions are drawn about the formation of intelligent, economically feasible, efficient, and environmentally oriented packaging manufacturing.

АННОТАЦИЯ

Статья посвящена исследованию особенностей цифровой трансформации процессов в производстве упаковочных изделий. Раскрыты тенденции роста и структурной диверсификации отрасли, выделены этапы производственного цикла (исследование, производство, управление и логистика) и направления их цифровизации. Представлена концептуальная модель цифровой трансформации, предполагающая системное и связанное использование технологий и повышение эффективности производственных процессов. Определены принципы эффективной организации упаковочного производства (поточность, рациональность, изменчивость, интеграция систем качества и экологии, инновационность). Сделаны выводы о формировании интеллектуального, экономически целесообразного, эффективного и экологически ориентированного производства упаковочных изделий.

Keywords: packaging production, digital transformation of packaging manufacturing, packaging market, technology implementation in packaging, digitalization of production systems.

Ключевые слова: производство упаковочных изделий, цифровая трансформация производства упаковки, рынок упаковки, внедрение технологий в упаковку, цифровизация производственных систем.

Introduction. Modern packaging production represents one of the most dynamically developing sectors of industry, for which trends such as digitalization, environmental orientation, and integration are highly relevant. The significance and relevance of packaging production from an economic perspective are determined not so much by the role of packaging as a means of preserving products, but rather by its additional functions—as a carrier of marketing, logistical, and often environmental information. Taken together, these factors render the packaging production industry a strategically important component of the contemporary economy.

Confirmation. The highlighted points are also reflected in the dynamics of the global packaging market. According to a study by Mordor Intelligence, the global packaging market is characterized by rapid growth and a high level of structural diversification. In 2025, its volume is estimated at USD 1.18 trillion, with a projected increase to USD 1.44 trillion by 2030, corresponding to a compound annual growth rate (CAGR) of 3.92% (Figure 1).

Figure 1. Dynamics of the global packaging market, USD trillion (forecast) [1]

The industry is characterized by high maturity while retaining the potential for innovative development, the prospects of which are explained by factors 1) the increasing role of e-commerce, 2) the growth in consumption of fast-moving consumer goods, and 3) the transition of companies to ESG-oriented production models, which stimulates the promotion of environmentally friendly packaging solutions. More than 40% of the global market volume is accounted for by the Asia-Pacific region, dominating due to cost savings achieved through economies of scale; developed regions (in particular, Europe and the USA) actively invest in waste recycling, monomaterial production, and digital printing (i.e., in high-tech areas). Market growth is also driven by continuous procurement and the rapid expansion of e-commerce shipments, stimulating increased demand for protective and versatile types of packaging. The contribution of these factors to the overall CAGR is estimated at approximately 1.2% and 0.9%, respectively, i.e., accounting for more than half of market growth [1]. At the same time, as noted in the study by S.A. Zykov, many of the global trends presented are becoming relevant in national contexts, taking into account the specifics of each market; overall, at the current stage, the main focus is on reducing material intensity, environmental orientation, and quality improvement [2].

In the context of the global packaging solutions market, the phenomenon of digitalization deserves particular attention. Today, a new paradigm of packaging production is emerging, in which, while maintaining growth in the main segments, the focus shifts toward technological renewal, digital management, and environmental modernization, which determined the choice of the subject and the formulation of the objective of the present study.

The aim is to examine the specific features of the impact of digital transformation on the main processes in packaging production.

Research methodology. The theoretical basis of the study consists of works by contemporary scholars that explore the essence, structure, and prospective directions of digital transformation in packaging solutions; based on systematization, theoretical analysis, synthesis of scientific literature, and modeling, the main aspects of digital transformation processes in packaging production have been identified.

Results and discussion. Considering packaging production as a process, it should be noted that it is characterized by a clear sequence of stages, the alternation of which ensures the implementation of the entire production cycle; at the same time, the efficiency of packaging production is determined by the coordination of technological operations, the quality of management, and the degree of implementation of digital tools, which in turn ensure transparency and process integration.

From the perspective of packaging production within the operational management system, as correctly noted by A. Regattieri and G. Santarelli, packaging serves as an element linking production and logistics processes (Figure 2). In this way, packaging ensures cost minimization, reduction of the production cycle time, and optimization of logistics flows. At the same time, packaging is considered an integrative subsystem, capable both of reducing costs and enhancing overall production efficiency [3].

Figure 2. Packaging production within the operational management system

Accordingly, the organization of packaging production is an important measure affecting the efficiency of the entire business model. In this regard, it is appropriate to consider the main stages of packaging production and their content (Figure 3).

The first stage is research and prototyping, during which materials are selected, forms are modeled, ergonomics and environmental friendliness are assessed; most importantly, the product’s cost is calculated. Accordingly, principles of engineering design and product life cycle analysis methods are widely applied—the effectiveness of a packaging solution depends on the correct choice of material combinations, balancing protective properties with weight reduction.

At the production stage, operations such as processing, forming, printing, laminating, and assembling packaging are carried out; just-in-time and quality management concepts are actively applied, aimed at eliminating waste, improving quality, and optimizing production flows. Lean manufacturing principles are implemented, with packaging considered not as a by-product, but as an element that creates added value.

Figure 3. Organization of packaging production and its main stages

At the third stage (organization and management), equipment scheduling, inventory management, supplier coordination, and distribution of finished products are carried out. Management information systems (ERP, CRM) are integrated, and economic performance indicators are formed (cost, profitability, capacity utilization rate).

At the final stage, packaging storage, transportation, and reverse logistics are carried out, with packaging serving as part of the physical flow and a factor in its efficiency; an effective logistics structure involves route optimization, reduction of order processing time, and the implementation of digital flow monitoring technologies.

Building on the presented packaging production cycle, we align with the theses of L. Maretto, M. Faccio, and D. Battin, who, based on the study of approaches to organizing real production, identify a range of promising and highly effective technologies, including IoT, big data and its analytics, AI, cloud solutions, simulations, 3D printing (additive technologies), and others [4]. These technologies, however, do not merely perform functional tasks but enable the transition to end-to-end integration of packaging production processes.

It follows that digital transformation in packaging production is characterized not merely by the implementation of individual technologies, but by the transformation of all stages of the product life cycle, structured as a coherent system. As correctly noted by J. Izquierdo, at the present stage, the priority is the concept of Industry 5.0 (a new phase of technological development in the packaging sector, in which fully automated solutions are replaced by a model of human–intelligent system interaction). According to him, the main focus should be on the synergy between humans, robots, and data, which in packaging production implies a shift from standardized to more flexible processes [5]. Similarly, a McKinsey study highlights the economic potential of implementing digital and analytics (DnA) technologies in the packaging industry. Based on a survey of representatives from leading companies, it was found that industry digital maturity remains low, yet the potential for efficiency gains is significant. Over 70% of respondents estimate the economic impact of DnA solutions as a possibility to reduce costs by 5% and increase revenue by 5–7%. Digitalization is most actively implemented in production, supply chain management, and human resource management [6]. Looking ahead, potential areas of development include 1) smart manufacturing; 2) digital logistics; 3) commercial analytics; and 4) environmental analytics.

According to W. Huang, the digital transformation process in packaging production can be divided into three main stages (Design, Production, Delivery), each forming its own technological ecosystem. Implementation results indicate that digitalization can reduce the production cycle by 20%, lower costs by 15–18%, and increase demand forecasting accuracy up to 90% [7]. Thus, exploring digital transformation proves to be highly relevant and effective (Table 1).

Table 1.

Exploring digital transformation

Based on Table 1, the theses of G.F. Massari, R. Nacchiero, and I. Giannoccaro appear promising, as they argue that digital technologies in packaging contribute to the implementation of four directions of circular and lean resource management [8]:

• Closing flows using IoT and blockchain to track the product life cycle of packaging and return materials to production;
• Slowing flows to extend the service life of packaging through predictive maintenance and the selection of more efficient materials;
• Narrowing flows to increase the efficiency of raw material use through AI optimization;
• Dematerialization through the implementation of digital services that replace physical carriers (electronic labels, QR coding).

Thus, a conceptual model of digital transformation processes in packaging production is formed (Figure 4).

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Figure 4. Conceptual model of digital transformation processes in packaging production

As practical factors for implementing this model, a number of recommendations can be highlighted—principles for the effective organization of packaging production and support through digital transformation:

• Implementation of a flow-oriented structure with minimal downtime (achieved through the use of the Internet of Things (IoT) and Manufacturing Execution Systems (MES);
• Rational use of raw materials and supplies (achieved through the application of Big Data to analyze waste and secondary streams, the use of 3D printing for precise production of molds and custom components, implementation of AI, and blockchain integration);
• Adjustability of production lines for orders of varying volumes (enabled by modular equipment architecture and virtual management of production systems);
• Integration of quality and environmental management systems;
• Innovation and systematic implementation of intelligent solutions (combined application of technologies to achieve maximum effects).

Conclusion. Thus, based on the results of the conducted study, the following features of digital transformation processes in packaging production can be identified:

1. the integration of economic, technological, and environmental priorities in the development of the packaging market;
2. the organization of production is structured as a system encompassing research, manufacturing, management, and logistics, whose efficiency is ensured by methods of operational management and the principles of lean manufacturing;
3. digital transformation affects all stages of the packaging life cycle and relies on the integration of technologies such as IoT, AI, Big Data, and 3D printing;
4. the process should be guided by the fundamental principles of effective organization—flow continuity, rationality, adaptability, integration, and innovation;
5.  as a result of digital transformation, an intelligent, economically feasible, efficient, and environmentally responsible packaging production system is formed.

References:

1. Packaging Market Size & Share Analysis – Growth Trends and Forecast (2025–2030) [Electronic resource]. (2025). Available at: https://www.mordorintelligence.com/industry-reports/global-packaging-market
2. Zykov, S. A. (2019). Main trends in the development of the packaging market. Packaging as a tool for product promotion. Food Industry, 2(40), 40–44.
3.  Regattieri, A., & Santarelli, G. (2013). The important role of packaging in operations management. In Operations Management (pp. 183–219). https://doi.org/10.5772/54073
4. Maretto, L., Faccio, M., & Battini, D. (2023). The adoption of digital technologies in the manufacturing world and their evaluation: A systematic review of real-life case studies and future research agenda. Journal of Manufacturing Systems, 68, 576–600. https://doi.org/10.1016/j.jmsy.2023.05.009
5. Izquierdo, J. (2024). Industry 5.0: The Packaging Paradigm Shift [Electronic resource]. Available at: https://www.packagingtechtoday.com/machinery/robotics-automation/industry-5-0-the-packaging-paradigm-shift/
6. Diakhaby, M., Feber, D., Goel, A., & Nordigården, D. (2021). Wrapping up digital and analytics: Current value-creation opportunities for packaging players [Electronic resource]. McKinsey & Company. Available at: https://www.mckinsey.com/industries/packaging-and-paper/our-insights/wrapping-up-digital-and-analytics-current-value-creation-opportunities-for-packaging-players
7. Huang, W. (2025). Digital transformation in the packaging industry: From design to delivery. Innovation in Science and Technology, 4(5), 35–41. https://doi.org/10.63593/IST.2788-7030.2025.06.003
8. Digital technologies for resource loop redesign in circular supply chains: A systematic literature review. Resources, Conservation & Recycling Advances, 20, Article 200189. https://doi.org/10.1016/j.rcradv.2023.200189