Recent years have seen remarkable developments in the bakery industry, particularly in process and packaging machines, as well as in technical and structural innovations. Consumers increasingly demand sustainable packaging, a shortage of skilled labour is making automation essential, and energy and material efficiency are becoming competitive factors. As a result, modern packaging solutions for bread, croissants, rolls, cakes, and other baked goods must be ecological, economical, and technologically flexible in equal measure.
Sustainability is central. Many manufacturers focus on recyclable, compostable, or bio-based materials such as paper-based solutions, PLA films, or monomaterials. For instance, interpack exhibitor Weber Verpackung presents its Baker Bag for self-service counters, made of paper and optionally fitted with transparent windows made of recycled film or glassine. A bag with a glassine window can be fully recycled through waste paper collection. Nevertheless, product protection remains paramount, ensuring that baked goods maintain freshness. Innovative packaging systems therefore combine hygiene and shelf life with sustainability, often relying on barrier functions to control water vapor and oxygen exchange. Even when paper packaging is used, a thin plastic coating or polymer-containing layer is required, though overall plastic content remains lower than conventional foil bags.
Automation is advancing alongside material innovation. Robotics and AI are increasingly integrated into production, enabling precise, gentle handling of delicate baked goods. Camera-supported systems analyse product shape, position, and quality in real time, ensuring that only flawless items are packaged, reducing waste and increasing reliability. Shorter changeover times are particularly important for smaller batches and frequently changing product variants. At Interpack 2026, these technological advancements will be showcased to a broad trade audience.
Digitalisation enables networks of machines, sensors, and control systems, forming intelligent production ecosystems. Process data such as temperature, sealing quality, or material consumption are continuously monitored and analysed. AI-based platforms like VisionAI detect deviations instantly and adjust parameters in real time, while predictive maintenance reduces downtime. Such smart factory concepts are no longer exclusive to large manufacturers but are increasingly adopted by medium-sized enterprises.
The new Syntegon counting feeder groups biscuits particularly gently and places them in cardboard or plastic trays or in flowpackers.
(Image: Syntegon)
Robotics and sensor-based systems excel with sensitive or irregularly shaped products. Gerhard Schubert GmbH’s Cobot tog.519 combines AI-supported image recognition and flexible robot kinematics, handling up to 90 cycles per minute and accommodating new product molds via 3D-printed tools, which reduces changeover times and investment costs. Syntegon’s FGCT counting feeder gently groups biscuits for trays or flowpackers, reducing waste while ensuring efficiency. Fuji Packaging’s Alpha Wrapper systems handle sensitive baked goods efficiently with minimal material use, offering resealing and easy-opening options. Sacmi Packaging & Chocolate provides high-speed flow-wrapping solutions for snack pies using heat-sealable paper films, complemented by compact secondary packaging systems like the IER 030 toploader and F-EL carton erector.
With the Fuji Alpha Wrapper, sensitive bakery products can be packaged efficiently and in a material-saving manner.
(Image: Fuji Packaging)
Multivac’s Cooling@Packing system integrates vacuum cooling directly into thermoforming packaging, allowing immediate packaging after baking. This method saves energy, reduces space requirements, and limits contamination risks.
From 7 to 13 May 2026, Interpack visitors in Düsseldorf will experience live demonstrations of modern, intelligent bakery packaging solutions.