The biggest challenge faced by food manufacturers today is no longer simply how to produce more, but how to produce smarter, faster and more consistently with fewer operational constraints. Rising labour costs, workforce shortages, pressure on production efficiency and increasingly demanding sustainability requirements are forcing manufacturers to rethink how their facilities operate. From food processing and primary packaging to case packing, palletising and final dispatch, the need for connected, automated operations has never been greater.

As the industry moves beyond standalone machinery towards integrated production ecosystems, automation, artificial intelligence and localisation are emerging as critical drivers of competitiveness. For manufacturers, the real opportunity lies not just in automating individual processes, but in connecting the entire production value chain.

At PackMach Asia 2026, held from 28 to 30 October in Mumbai, Mr Anthony D’Souza, Managing Director, Duravant India, shared his perspective on this transformation, explaining how integrated automation, technology upgrades and stronger local capabilities can help Indian food processing and packaging manufacturers address emerging challenges and prepare for the next phase of industrial growth.

PackMach Asia: An evolving platform for processing and packaging technologies

Reflecting on the exhibition's growth, Mr D’Souza observed that PackMach Asia has developed considerably since its inception under IPMMI, with the support of Messe Munchen India (MMI). The exhibition has grown year after year, attracting equipment manufacturers and technology providers from the processing, beverage and packaging industries.

The addition of Pro Food has further broadened its scope, bringing more companies and solutions into the food processing segment. He believes the platform's strength lies in bringing equipment manufacturers together and providing customers with greater exposure to technologies that can add value to their businesses.

"PackMach Asia is a platform that continues to evolve and grow, helping customers understand the importance of equipment and how it can add value to their organisations," he said, expressing confidence in its continued growth.

Automation becomes essential amid labour and productivity challenges

The pressure to maintain productivity while controlling operational costs is making automation increasingly important. Mr D’Souza noted that the COVID-19 pandemic exposed the vulnerabilities of manpower-dependent production systems, with companies facing workforce availability challenges and declining productivity. Rising labour costs and changes in labour regulations have further strengthened the case for automation.

According to him, dependability, reliability and continuous productivity are the three fundamental factors driving automation adoption.

Traditional production systems relying heavily on manual labour can experience interruptions due to illness, festival-related workforce shortages and variations in operational efficiency. Automation helps address these challenges through consistent production, improved accuracy and greater reliability.

However, Mr D’Souza emphasised that automation should not be viewed as a complete replacement for the workforce. Instead, it enables employees to move from repetitive, unskilled tasks towards more skilled operational responsibilities.

"Unskilled jobs can be handled by automation, while skilled workers can focus on operating equipment, implementing processes, ensuring productivity and managing other critical operations," he explained.

He believes skilled manpower will remain essential in automated manufacturing environments, particularly for equipment operation, process management and production optimisation. "Automation is the future, and it will drive every industry towards success," he added.

End-of-line automation: Completing the production equation

While manufacturers increasingly invest in advanced processing and primary packaging equipment, Mr D’Souza believes end-of-line automation deserves equal attention.

Activities such as placing products into cartons, case sealing, palletising and preparing packages for dispatch have traditionally depended on manual labour. These repetitive operations are particularly vulnerable to workforce shortages and inconsistencies.

Automating these processes through case packers, palletisers and material handling systems can help manufacturers achieve consistent output and uninterrupted productivity.

Mr D’Souza pointed out that manufacturers often evaluate automation investments by comparing equipment costs with labour expenses. However, this overlooks the wider benefits of automation. "When you consider productivity and consistency, automation delivers significant benefits," he said.

He also stressed that end-of-line capabilities must match the performance of upstream production equipment. Sophisticated processing machinery cannot deliver its full potential if products cannot be efficiently packed, handled and transferred. Integrated end-of-line solutions therefore play a critical role in connecting packaging lines with warehousing and dispatch operations.

An integrated portfolio spanning processing to final dispatch

Duravant addresses market requirements through two broad categories: food automation and industrial automation.

As Mr D’Souza explained, food automation primarily addresses processing applications involving potatoes, French fries, chips, protein-based products and other food categories. Industrial automation complements these capabilities through packaging, end-of-line and material handling solutions.

Following processing, products can be packed into flexible pouches, cartons and other formats before moving through case packing, material handling, warehousing and dispatch. Mr D’Souza cited examples within the company's portfolio for flexible pouch and cartoning applications.

This breadth enables Duravant to address customer requirements across multiple production stages rather than supplying individual machines for isolated operations.

"Our strength and USP is that we can address a customer's requirements right from the beginning of product processing through to final dispatch," he said.

Integration: Addressing a key challenge for Indian manufacturers

One of the significant challenges facing Indian manufacturers is integrating equipment procured from multiple suppliers. Although individual machines may perform efficiently, inadequate connectivity and coordination between them can restrict overall production efficiency.

Mr D’Souza believes manufacturers need partners capable of delivering complete, integrated systems rather than simply supplying individual machines.

Duravant follows this approach even when certain components must be sourced from other manufacturers. For instance, while the company may supply approximately 80% of the equipment required for a production line, specialised components such as checkweighers, printers and camera systems can be sourced from other suppliers and integrated into the overall solution.

This provides customers with a single point of coordination for their automation requirements. The approach also supports manufacturers that already operate equipment from different suppliers but want to automate additional production stages.

"Duravant believes that integrated solutions are the future. Customers do not need to run around looking for different suppliers. They can simply approach us, and we will be happy to support them," Mr D’Souza said.

Sustainable packaging through material and equipment optimisation

Sustainability is increasingly influencing packaging decisions, with manufacturers exploring ways to reduce material consumption and transition towards more sustainable formats.

Mr D’Souza highlighted wraparound case packing as an example of packaging optimisation. Traditionally, manufacturers have used pre-erected Regular Slotted Container (RSC) cartons. Wraparound case packing offers an alternative in which packaging material is wrapped around products, helping optimise material usage.

In flexible packaging, manufacturers are also exploring alternatives to conventional non-recyclable laminates. Duravant works with customers to retrofit existing equipment or develop new solutions compatible with alternative materials, including recyclable and biodegradable films, as well as water-soluble films for pod applications.

According to him, equipment efficiency is another important consideration. High-speed packaging systems can potentially replace multiple machines while delivering the required production output. Although these systems may require higher initial investment, they can offer long-term benefits through reduced manpower requirements, lower energy consumption and better utilisation of factory floor space.

AI and technology upgrades: Preparing for the next phase

Mr D’Souza believes continuous technology upgrades are essential for manufacturers to remain competitive. While many customers continue operating food processing equipment purchased a decade ago, newer technologies offer opportunities to improve performance and productivity.

Duravant regularly engages with customers to communicate technological developments and help them evaluate when upgrading or replacing existing equipment may be appropriate.

Artificial intelligence is another emerging focus area. Mr D’Souza confirmed that the company has started incorporating AI into its packaging and processing machines to minimise operational time and support equipment operations.

He views AI as a tool for enhancing human capabilities rather than a threat to employment.

"AI should be used to our advantage, not to our disadvantage," he said, encouraging manufacturers and professionals to embrace technological developments and use them to improve productivity and output.

Localisation: Strengthening commitment to the Indian market

According to Mr D’Souza, localisation remains a key priority in Duravant's Indian market strategy. Alongside introducing global technologies to domestic manufacturers, the company is strengthening local service capabilities to improve customer accessibility and responsiveness.

Duravant has expanded its Indian service team, reducing dependence on engineers travelling from Europe for customer support. The company is also localising spare parts, establishing its own warehouse and beginning local manufacturing of selected spares.

The company plans to gradually extend localisation to equipment manufacturing, starting with smaller machines before expanding into additional equipment categories.

For Mr D’Souza, localisation is about delivering the same quality standards at more economical prices while making service and support more accessible to Indian customers.

Automation and localisation will shape industry growth

Concluding the interaction, Mr D’Souza expressed confidence in the long-term growth prospects of the food processing and packaging industries, supported by population growth and increasing demand for food products.

However, he cautioned that manufacturers must remain adaptable as technologies, customer expectations and operational challenges continue to evolve. Companies unwilling to upgrade their technologies risk falling behind, while those investing in continuous improvement will be better positioned to capture emerging opportunities.

"Localisation is the need of the hour, and automation is the essence of this journey," he said.

For Duravant India, the focus remains on combining advanced technology, integrated automation capabilities and localisation to help manufacturers improve productivity, operational efficiency and long-term competitiveness.