Digital Transformation in Plastics Industry: Towards the Smart Factory

The plastics and packaging sector is undergoing a profound transformation. The demands of the circular economy, regulatory pressure and the demand for more conscious customers are pushing companies to rethink their processes.

For SMEs, digital transformation in the plastics industry has become an essential step to remain competitive. Digitisation enables factories to transition from manual processes, which have a high margin of error, to smart factories where everything is controlled in real-time and without paper (paperless digitisation in factories).

Solutions such as MES and ERP systems, as well as web-based industrial management platforms, enable the monitoring, automation, and optimisation of each phase of production. Thus, companies not only comply with regulations and reduce costs, but also gain in sustainability, efficiency and responsiveness to the market.

Challenges for plastics and packaging SMEs

The digital transformation responds to specific challenges that limit the competitiveness of SMEs in the sector.

Manual processes and a lack of visibility

In many factories, paper records or spreadsheets are still used to control production. This generates:

• Human errors in data entry.
• Lack of real-time visibility on the status of machines and lines.
• Difficulties in detecting incidents or stoppages at the right time.
• Slow response times to quality problems.

Industrial software for production control eliminates this dependence on paper, thanks to automatic recording of production data and digital notifications for operators.

Regulatory pressure and recycling

The circular economy has put the sector in the spotlight. It is now essential to ensure:

• Recyclability of materials and waste control.
• Reduction of scrap and use of plastic trimmings through internal recycling.
• Transparency throughout the production chain to comply with audits and certifications.

SCADA systems integrated with MES/ERP enable companies to trace each batch of material from its origin, measure consumption, and demonstrate compliance with sustainability goals.

Impact of MES/ERP in plastics

The implementation of an MES or ERP system in plastics and packaging plants brings tangible benefits.

Reduction of packaging waste

Thanks to real-time monitoring in factories, companies can detect deviations in critical parameters and act immediately. This translates into:

• Less production of defective parts.
• Reduction of operational errors in the plant.
• Reduced costs due to material waste.

In a thermoforming line, for example, an MES specialised in plastics can control pressure and temperature parameters to avoid defects in complete batches.

Mould optimisation and scrap control

Moulds and dies are the heart of the plastics industry. With an MES system for plastics, it is possible:

• Measure the performance of each mould in real time.
• Identify those that generate more scrap.
• Plan preventive maintenance to extend their useful life.
• Apply design improvements based on historical data.

In this way, the company not only reduces costs but also increases its production efficiency.

Improving batch traceability

Traceability is critical in an industry where defects can affect thousands of packages. A web-based industrial management system makes it possible to:

• Automatically record the origin of each batch of material.
• Link it to production parameters and quality controls.
• Access complete records in seconds in the event of an audit.

With this approach, SMEs can not only comply with regulations but also gain the confidence of customers and distributors.

Tangible benefits and ROI

Digital transformation in the plastics and packaging industry brings clear and measurable benefits:

• Reduced waste and scrap with real-time data.
• Optimisation of moulds and machinery through predictive maintenance.
• Paperless, more agile and reliable digital plant management.
• Regulatory compliance and fast audit preparation.
• Continuous improvement through historical data and advanced analytics.

Return on investment (ROI) in MES/ERP systems typically occurs in under 18 months, especially in high-volume production plants.

The time to digitise your plant is now. With the help of Overtel, a technology partner specialised in industrial digitalisation and MES/ERP solutions, any SME in the plastics sector can become a smart, sustainable and competitive factory, with measurable results from day one.

Request a free INEXION demo and discover how to reduce waste, optimise your machinery and make the definitive leap towards Industry 4.0.