It’s Time to Talk: Why CPGs Need to Prioritize Communication & Exploration in 2025

Modular cost-effective components within a factory floor can not only free up space for additional resources, but can ultimately save money on purchasing potentially unnecessary components. Image courtesy of Bosch Rexroth.

By Krupa Ravichandraan, Bosch Rexroth Sales Product Manager

As we enter 2025, we’re at a unique inflection point in the future of CPG manufacturing. Understandably, many end-users are proud of how they’re leveraging proven processes and technologies that have propelled them to profitability. What will undoubtedly be a common thread among the most successful of those in the future, however, is how they weave in measures of exploration and openness. An efficient and high-performing production line has a perfect harmony between the different machines that are connected with each other through conveyors; and communicates via controls systems similar to a well-functioning human body — all parts are functioning harmoniously through proper communication of signals from the brain and blood flow from the heart.

That synchronicity and transparency, both within the components of an assembly line, and between OEMs, system integrators, and end-users should be sought after by the most innovative of manufacturers. Those who are willing to do so through the actions below will be able to best adapt to a constantly shifting consumer landscape that continues to define this industry.

Multifunctional Modularity

One of the buzzwords that floated around PACK EXPO in 2024, and continually comes up in conversations throughout the consumer packaged goods (CPG) industry, has been modularity and sustainability. Many end-users in the United States recognize the industry regulations and compliance standards that exist overseas and that it’s only a matter of time before such protocols are commonplace here. As such, there’s a growing need for components and sub-systems that can not only serve an identified purpose but can be reformatted or adjusted to serve a different function and help meet a throughput goal. Modular cost-effective components within a factory floor can not only free up space for additional resources, but can ultimately save money on purchasing potentially unnecessary components. A perfect example of this is in the backbone of many CPG lines – conveyors. While many CPG manufacturers immediately trend towards stainless steel and highly custom solutions when not a requirement, many modern conveyors are composed in part, or entirely, of aluminum framing, which is both a cost-effective and sustainable solution because of its modularity and reconfigurability. This helps with reduction of carbon footprint too. By exploring every conceivable adaptation of a solution before purchasing, end-users can better understand the true cost of ownership and potential return of investment in machinery that may be able to accomplish more than they originally thought.

Monolithic systems are being phased out for a much more flexible network that can isolate issues faster without it impacting other sections of a process. Image courtesy of Bosch Rexroth.

Controlling the Narrative

Naturally, how those flexible solutions communicate with each other throughout a line is equally important, which highlights yet another key factor in the evolution of manufacturing. Open control systems are advancing in parallel to their hardware counterparts and it’s impressive to see their increased utilization among end-users, including through app-based software. They can integrate seamlessly to existing ecosystems, which speaks to their value and aligns with the adaptability mentioned above.

Monolithic systems are being phased out for a much more flexible network that can isolate issues faster without it impacting other sections of a process. It’s worth noting that there are some manufacturers who are resistant to the shift to a more open control landscape, in some cases because of a workforce that has operated in a previous system for years. It’s therefore incumbent on companies that are considering implementing a new control system that they do their due diligence and serve as advocates to their workforce on why such a change is being made. It represents a valuable opportunity to connect that operator or programmer with the system integrator and even the OEM that produces that system in a concerted effort to improve communication and subsequent productivity.

Silos Surrendered

The lines between those three parties are somewhat blurred, which is for the better, particularly when considering maintenance issues. Because subsequent data collection and management is a critical advantage to many advanced solutions, end-users need a guide to navigate the mass of metrics and translate it to actionable steps. Whether that’s through the system integrator and/or the component manufacturer, there needs to be a copacetic relationship in identifying the right data that needs to be tracked and addressing potential issues before they arise. It’s a more proactive position to be in, which can reduce downtime and resources spent addressing issues and can ultimately extend the life of a particular component.

While the steps forward aren’t always as clear as one solution over the other, it’s evident that manufacturers who prioritize communication with strategic partners and open network solutions give themselves added luminance to see the path forward. The United States remains the largest market in the world for consumer packaged goods and although other countries are catching up, we have the opportunity and, perhaps, responsibility to be the pioneers in pushing the boundaries of collaboration and innovation.

About the Author

Krupa Ravichandraan is the Sales Product Manager – VarioFlow plus and ACTIVE Shuttle at Bosch Rexroth. Learn more at www.boschrexroth-us.com/assemblytechnology.

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