Andreas Schildknecht
Global Product Manager
Syntegon

Machines that communicate with each other and self-learning systems that optimize production processes: What sounds like science fiction is already gradually becoming a reality in the food industry. The industry is at a turning point. It’s not just about technological advancement, but about fundamentally changing how food is produced, processed and packaged. At the same time, the industry is facing major challenges. Demographic change is leading to a growing shortage of skilled workers – by 2030, around 1.2 million jobs in food processing will remain unfilled in Europe alone. While energy costs continue to rise, regulatory requirements are also increasing. Now is the time for companies to fundamentally rethink their production environments – and become smarter, more connected, sustainable and flexible than ever before. So, what does the “Factory of the Future” look like, capable of meeting these demands?

What’s Driving the Change

Demographic change is already having a decisive impact on the food industry. According to a study by the European Commission, more than 75 percent of companies report difficulties in finding qualified staff. The situation is compounded by the age structure: fewer young professionals are entering the workforce while many experienced employees are heading toward retirement. Technical professions are particularly affected. As the demands for technical know-how increase, the skills gap widens. Automation is no longer optional – it has become a necessity: not only to increase efficiency, but to secure production altogether.

The economic environment has also changed dramatically. Energy and raw material prices are on the rise while inflation is putting additional pressure on margins – making efficiency gains more critical than ever. At the same time, sustainability has become a key driver of transformation. Regulatory developments such as the EU Green Deal and the Packaging and Packaging Waste Regulation (PPWR) are setting new standards, while consumer expectations also continue to rise. Recent and ongoing global crises have also exposed the vulnerability of supply chains: Flexibility, rapid switching to alternative raw materials, adaptable production lines and digital transparency throughout the value chain are becoming essential success factors.

These drivers have created a momentum that calls for profound transformation. The strategic response: the “Factory of the Future” – a production environment that leverages intelligent technologies, a high degree of automation and connectivity to meet the demands of tomorrow.

The Five Pillars of the Factory of the Future

The Factory of the Future is built on five key pillars, creating a new paradigm for food production.

1. Intelligent automation

Modern automation systems combine sensor technology and AI to handle complex tasks. AI-based quality assurance detects deviations with precision and provides real-time alerts on where and how to correct them. These technologies counteract the skilled labor shortage by boosting productivity while maintaining high quality standards. In the next step toward the Factory of the Future, machines communicate with one another to correct process deviations autonomously – without operator intervention.

2. The Industrial Internet of Things (IIoT)

The IIoT connects machines and systems into a communicating network. Sensors continuously capture process data for real-time optimization, while predictive maintenance identifies issues before they cause downtime. This connectivity forms the foundation for autonomous production systems.

3. Data-driven production

The foundation for all this is data. Analytical tools turn raw data into insights that form the basis for all levels of decision-making. Edge and cloud computing provide the required technical infrastructure. This approach not only optimizes existing processes, but also opens the door to new business models.

4. Sustainability as a core principle

Sustainability is an integral part of modern production: intelligent control systems optimize energy consumption, resource-efficient solutions reduce material usage, and circular economy approaches minimize waste. Environmental responsibility can be aligned with business benefits – to reduce costs, comply with regulations, and strengthen brand image.

5. Flexibility and scalability

Adaptable systems allow for rapid product changeovers, while modular systems offer future-proofing: new technologies can be integrated and systems scaled without the need for complete rebuilds.

Together, these five pillars form an integrated overall concept that connects innovation with strategic business objectives. Syntegon supports food manufacturers in integrating various automation concepts into their specific production environments.

The Changing World of Work in the Factory of the Future

The Factory of the Future transforms not only production processes, but also the working world. Job  roles and tasks in production will change fundamentally – employees will evolve from machine operators to decision-makers. Physically demanding, repetitive tasks will increasingly be taken over by machines, while responsibilities such as process analysis, quality management and cross-system optimization will come to the force. This shift is creating more attractive job profiles, as complex technologies are becoming easily accessible thanks to new intuitive assistance systems. At the same time, new skillsets are required: the ability to interpret data is becoming increasingly important. The aim is to empower employees to fully realize the potential of the Factory of the Future. This new world of work combines the best of both worlds – the precision and efficiency of automated systems with human decision-making power. This synergy is key to sustainable competitiveness.

The Road to the Factory of the Future

The transformation toward the Factory of the Future doesn’t happen overnight. Instead, it is worth taking a pragmatic approach that builds on existing strengths while gradually integrating new technologies. The first step is to assess the current situation and analyze the potential by recording systems and processes. Prioritizing measures based on effort, benefit and strategic relevance is critical. This analysis forms the basis for investment decisions. From there, companies can implement new technologies step by step. Smart retrofitting of existing equipment is an ideal starting point: even older machines can be integrated into the connected production environment without major new investments.

Another key success factor: involving employees - right from the beginning. Participating in the design of new workflows fosters acceptance and leverages the experience of the workforce. The Factory of the Future doesn’t happen overnight. Strategic development and continuous improvement are the path that every company must take. Syntegon accompanies customers on this journey as a partner – with technological expertise, industry know-how and a focus on measurable results.

The Factory of the Future as a Continuous Process

The Factory of the Future is not a fixed goal, but rather an ongoing evolution. Autonomous production lines are already a reality in many companies. Self-optimizing processes that independently respond to changing conditions and continuously improve performance are on the verge of a breakthrough. Sustainability will continue to gain momentum – driven by innovative materials, new technologies and growing demand. Bio-based packaging, energy-autonomous systems and closed resource cycles are key areas of development. Data-driven services, predictive maintenance as a service, and flexible production capacities on demand are changing the value chains.. Syntegon is actively shaping this future – through in-house research and development and close dialogue with customers and partners. The aim is to develop technologies that are not only highly innovative, but also economically viable and sustainable. At the core of the Factory of the Future is the intelligent connection between people, machines and data – for efficient, sustainable and future-ready production. This vision is the future that Syntegon is building together with its customers.

Syntegon is a leading global technology company and strategic partner to the pharmaceutical, biotech and food industries. With a strategic focus on the growing pharmaceutical and biotech sectors, Syntegon plays a vital role in global healthcare, providing in-depth process expertise and mission-critical technologies for the safe, efficient, and compliant production of essential medicines. In the food sector, Syntegon is recognized for high-speed, high-precision packaging solutions, drawing on unique engineering excellence to help manufacturers improve performance and product quality. Its global service business supports about 75,000 installed systems with a comprehensive lifecycle offering, ensuring uptime, efficiency, and long-term value.

In fiscal year 2024, Syntegon generated 1.6 billion euros in sales. Headquartered in the Stuttgart region in Germany, the company employs 6,900 people at 47 locations in more than 20 countries. With over 160 years of industry expertise, Syntegon delivers solutions that make a real difference, helping people live better, stay healthier, and trust the products they rely on every day. 

* Andreas Schildknecht serves as Global Product Manager at Syntegon. He joined Syntegon in 2006. With over 25 years of industry experience, he specialises in food packaging solutions, particularly baking applications.