Today, the packaging industry faces a dual challenge: on one side, responding to significantly rising energy costs, and on the other, reducing its environmental impact. In this scenario, energy efficiency becomes a strategic factor for maintaining competitiveness, managing operational costs, and achieving the environmental objectives outlined in sustainability reports.
According to various estimates, energy costs can account for up to 20% of the total operational expenses of a packaging production line. Therefore, careful energy management is clearly a key factor in improving profitability and simultaneously reducing CO₂ emissions.
Let’s explore in detail how to achieve improved energy efficiency in the packaging industry through technological, operational, and management strategies.
1. The role of energy in packaging production processes
Energy is a critical component in the packaging production process. Packaging machinery, automated lines, heating systems, air compressors, chillers, and lighting systems all significantly impact energy consumption.
As highlighted by a study published by the University of Padua (Unipd), many packaging companies still have considerable room for energy improvement. Identifying these inefficiencies is the first step towards targeted and measurable actions.
The phases consuming the most energy include:
- Forming and thermoforming
- Sealing and welding
- Drying and heat treatment
- Automated and robotic handling
Optimizing these phases results in substantial economic savings and significant reductions in pollutant emissions.
2. Measuring and monitoring energy efficiency in packaging
The first step to improving energy efficiency is accurately understanding the energy consumption of each machine and processing phase. This requires advanced energy monitoring systems based on the Internet of Things (IoT) and intelligent sensor technologies.
Implementing these monitoring technologies enables companies to:
- Obtain detailed real-time energy data
- Identify energy waste and operational inefficiencies
- Establish priorities for targeted corrective actions
- Track the return on investment (ROI) of implemented measures
Thanks to energy dashboards, production managers can immediately address anomalies and maintain operational efficiency over time.
3. Main technological solutions for energy efficiency
The packaging industry offers numerous technologies capable of significantly reducing energy consumption. The main technical solutions include:
Intelligent automation systems
Implementing artificial intelligence-based control systems allows automatic optimization of machinery energy consumption by adjusting production speeds and cycles according to actual needs.
High-efficiency electric motors and servo drives
Replacing traditional motors with high-efficiency IE4 or IE5 electric motors can achieve energy savings between 20% and 40%.
Optimized air compressors
Compressed air accounts for up to 15% of total packaging line energy consumption. Variable speed compressors (VSD) and reducing leaks in pneumatic networks present significant opportunities for energy savings.
Intelligent LED lighting
Replacing traditional lighting with intelligent LED systems can reduce energy consumption related to facility lighting by up to 70%.
4. Predictive maintenance and cycle time reduction for energy efficiency
Reducing production cycle times can significantly contribute to energy efficiency. Shorter cycle times mean less energy use per unit produced.
At the same time, implementing predictive maintenance strategies helps maintain machinery in optimal conditions, avoiding energy waste due to friction, vibrations, or unnoticed wear. Intelligent sensors and predictive analysis tools enable targeted interventions before inefficiencies or breakdowns occur.
5. Transition 5.0: towards energy-sustainable packaging
The Transition 5.0 Plan represents a strategic opportunity for the packaging sector, thanks to incentives for digitalization and energy transition.
Companies can benefit from tax breaks and funding to implement advanced energy efficiency technologies such as:
- IoT systems for intelligent energy management
- Digital Twins for preventive energy simulations
- Energy storage systems and energy recovery from processes
6. Low-carbon packaging for food manufacturing
The increasing demand for low-carbon packaging in the food sector requires highly energy-efficient packaging systems.
The packaging industry can respond with specific solutions:
- Packaging machinery powered by renewable energy sources
- Thermoforming and sealing systems with low energy consumption
- Implementation of cogeneration and trigeneration solutions for combined heat and power production
7. Conclusions: energy efficiency as a competitive and environmental lever
Energy efficiency in the packaging sector is now an essential factor for remaining competitive in the global market. Investing in energy-saving technologies, tools, and strategies generates direct and indirect economic benefits:
- Reduced operational costs
- Increased company profitability
- Significant reduction of CO₂ emissions
- Enhanced corporate reputation through stronger sustainability reports
Packaging companies that strategically approach energy efficiency will not only meet current global energy challenges but will also secure a lasting competitive advantage in the marketplace.
Do you want to explore the best technologies and strategies to improve energy efficiency on your packaging production line? Smart Packaging Hub is your go-to reference to discover concrete, innovative, and sustainable solutions for your business.