Demand for packaging keeps climbing as e-commerce grows, retailers reset their strategies, and brands push for better print quality and faster speed to market. From advanced converting machinery to intelligent automation and sustainability-driven innovation, box plants are investing in technologies that maximize productivity while navigating tighter margins and increasing production complexity.
Looking ahead to 2026, several major trends will define the next chapter of corrugated manufacturing.
1. High-Speed, High-Performance Machinery Is Becoming the Expectation
Converters are putting a stronger focus on machinery that delivers higher throughput while maintaining accuracy and consistency. Newer rotary die cutters and flexo folder gluers are being engineered with stronger frames, full-servo-driven components, and enhanced automation.
Full-servo FFGs capable of running 500 KPM and heavy-duty rotary die cutters like the SUN625HD reflect what box plants are asking for: equipment that improves setup times, repeatability, and overall print and fold quality with less operator intervention. Upgrading machinery is no longer a long-term aspiration. For many converters, it has become a near-term, strategic priority.
2. AI and IIoT Will Drive the Next Wave of Plant Optimization
Data has become essential to daily operations in a modern box plant. The next few years will bring a notable increase in AI-enabled tools and IIoT platforms designed to help factories predict failures, optimize uptime, and reduce scrap.
Systems such as Helios provide real-time visibility into machine performance, vacuum levels, and maintenance needs. This type of insight makes it easier for operators and supervisors to stay ahead of problems, instead of reacting to them after the fact. The plants that adopt data-driven tools early will have an advantage in uptime, staffing, and long-term asset performance.
3. Labor Challenges Are Increasing the Need for Automation
Many plants are still navigating labor shortages and the loss of experienced operators. At the same time, newer workers expect clearer, simpler interfaces and easier training.
Automation is helping bridge this gap. Plants are investing in automated setup, robotic handling, more intuitive HMIs, and remote support tools. These upgrades do not replace people. They make it possible for smaller teams to run complex lines with more consistency. They also help reduce training time and support better retention.
4. Sustainability Is Now Part of Day-to-Day Operations
Sustainability has moved from a marketing theme to something that influences capital purchases and daily decision-making. Converters are looking for machinery that reduces waste, uses less energy, improves vacuum efficiency, and lasts longer under heavy production demands.
Brands are watching closely. Plants that can demonstrate lower waste, improved efficiency, and more responsible material use are in a stronger position to win and retain business.
5. OEM Partnerships and Integrated Solutions Are Becoming More Valuable
The industry is seeing more collaboration among machinery manufacturers. These partnerships make it easier for converters to access a full range of equipment and support without juggling multiple vendors.
SUN Automation Group’s partnerships with Latitude Machinery Corp. (LMC), PARA, and Kolbus give converters a broader lineup of converting solutions through a single point of contact. This creates a smoother experience for training, parts, service, and integration across the entire converting line.
6. Digital Finishing and Short-Run Capabilities Continue to Grow
Short runs, customization, and faster turnaround times are reshaping market expectations and production planning. More converters are adding digital finishing, specialty folder-gluers, and modular equipment that can be adapted as customer needs shift.
Flexibility is becoming just as important as speed. Plants are diversifying their output to serve both large-volume customers and the booming market for smaller, branded orders.
How Box Plants Can Stay Competitive in 2026
The corrugated industry’s future will be shaped by technology adoption, strategic machine investments, and the ability to make smart, data-driven decisions. Converters who focus on the following areas will see the most meaningful gains:
✔ High-performance machinery
✔ Automation that supports operators
✔ IIoT and Predictive maintenance
✔ Workforce training and retention
✔ Sustainable, efficient production practices
✔ Strong partnerships with trusted OEMs
SUN Automation Group remains committed to supporting this evolution with machinery, technology, and service that improve uptime, efficiency, and long-term performance for box plants worldwide.
