Why Future-Proofing Should Be Part of Every Automation Plan

Future-proofing isn't a buzzword. It's a strategy manufacturers are using to reduce risk, improve ROI, and ensure packaging lines scale with their business.

In Episode 6 of Wrapping Things Up, Director of Sales Nick Knapp unpacks what future-proofing actually looks like on the plant floor and why it goes far beyond machine speed.

What Is Future-Proofing in Packaging Automation?

Future-proofing your packaging line means designing in flexibility so your system can quickly adapt to new products, unexpected growth, or future phases of automation. It’s not about guessing what’s coming. It’s about being ready for change.

As Nick puts it, future-proofing is less about predictions and more about preparation. It’s a consultative approach that he and his sales team take to help manufacturers think ahead, and it starts by asking the right questions:

• Will your product mix change in the next year?
• Could new contracts increase throughput requirements?
• Will labor constraints impact your ability to operate current systems?

“We find asking questions earns us credibility with our customers. They’re really looking for someone to say, ‘This works for you today. Have you considered X? Have you considered Y?’ It can really help us peek around corners and get in front of some potential issues or needs on our customers’ behalf.”

– Nick Knapp, Director of Sales, Viking Masek

Why Manufacturers Are Thinking Ahead More Than Ever

Short-term decisions are expensive in the long run. That’s why strategic buyers today are weighing:

• Total cost of ownership (TCO)
• Return on investment (ROI)
• System compatibility and integration with future automation phases

Nick shares that most decision-makers aren’t just thinking about what works now—they want to understand how their packaging investment will serve them 3, 5, or even 10 years down the road.

“They are extremely interested in equipment as an asset on the production floor. More customers are making their purchasing decisions based on what it means for their ability in the future.”

What Are the Signs a Packaging Line Is Outdated?

There’s no single red flag that signals a packaging line is outdated. Speed is often a chief indicator, but Nick cautions it’s not the only one. 

“It doesn’t matter how fast a machine runs if it’s not running at all.”

 It’s critical to pay attention to:

• Frequent downtime or rising maintenance costs
• Controls or electronics that can’t integrate with newer systems
• Limited physical space to scale operations
• Operator-reliant processes vulnerable to labor shortages

Seeing the signs and acting on them can be two different things. There are business reasons that may delay equipment and automation decisions, but there are tradeoffs. 

“We encourage our customers to weigh maybe higher upfront capital costs against an often more expensive do-nothing scenario.”

Why Doing Nothing Costs More

Delaying upgrades doesn’t save money, and it usually costs more. When manufacturers wait too long, they often face:

• Expensive redesigns due to facility limitations
• Extended lead times on machines or parts
• Missed opportunities due to limited capacity

Nick shares a cautionary tale of a customer who waited to invest in their line. When demand spiked and they needed a fast retrofit, the cost ballooned to 2.6x the original estimate due to custom redesigns and limited space. 

"Doing nothing is still a decision, and it can be the most expensive one."

Balancing Flexibility and Redundancy

For co-packers and growing manufacturers, flexibility is key. This might mean machines that handle multiple formats. Or,  it could mean redundant lines that keep production moving if one line goes down.

“One customer may need a duplicate line to handle throughput. Another may have lengthy cleaning procedures or inexperienced operators, or maintenance teams. Line redundancy means you’re never technically fully out of production. It’s risk mitigation.”

Automation Trends Driving the Next Chapter

Understanding trends shaping packaging investment helps decision-making about when to pivot with new or updated equipment and automation. 

Nick points to consolidation in a lot of marketing verticals as fueling the need for flexibility in multiple formats, film types, and product types. With that comes a need for automating both functionality and information.

In terms of automation trends, there are a few underlying themes:

• Various types of “touchless” systems, such as barcode scanning or HMI panel recipes that auto-populate information to assist operators of various experience and skill levels
• Automatic changeovers performed or supervised by a production manager from a central location
• Smart data tracking and reporting that ties into ERP or warehouse systems 

Where to Start? Define the Goal.

Nick recommends manufacturers begin with a simple question: What are you trying to accomplish? Speed? Flexibility? Labor reduction? Then work backwards.

For some, that means a phased approach. For others, it means going all-in with a turnkey line. Either way, it starts with clear goals and a partner such as Viking Masek who can help model the right path forward.

Get more insights from Nick Knapp by listening to the full conversation on the Wrapping Things Up podcast. You can also catch up on past episodes that cover a broad range of topics.

FAQ: Future-Proofing Packaging Automation

What does it mean to future-proof a packaging line?

Future-proofing means designing packaging operations that can adapt to change in shifting product formats, evolving customer demand, new automation phases, or workforce constraints. It’s about making smart investments today that won’t limit your business tomorrow.

How can manufacturers tell when it’s time to upgrade their equipment?

Common red flags include increased downtime, excessive maintenance costs, lack of integration with ERP or QC systems, and an overreliance on operator intervention. If your equipment limits growth or flexibility, it’s time to evaluate a modernization plan.

What’s the risk of delaying automation decisions?

Waiting too long can lead to increased costs, longer lead times, and rushed customizations that could’ve been avoided. In many cases, “doing nothing” ends up costing more — in lost revenue, missed contracts, or unplanned downtime.