How COVID‑19 Accelerated Automation in the Plastics Industry

Plastics manufacturers, already grappling with a widening skills gap, were suddenly pressed to meet urgent demand for pandemic‑related products. Emergency production of items such as personal protective equipment (PPE) swiftly transitioned to full‑scale reshoring, prompting the public, brand owners, and OEMs to reassess the reliance on overseas sourcing amid supply chain shocks.

The reshoring momentum was further fueled by early‑2020 supply‑chain disruptions. Even before the virus reached U.S. soil, manufacturers witnessed delivery delays as numerous Asian suppliers closed amid local outbreaks.

North American injection molders were thrust into a whirlwind of competing pressures. Prior to the pandemic, talent shortages already strained operations; the added need for social distancing further compressed workforce capacity. In spaces where human‑heavy processes—such as secondary operations—were most affected, maintaining throughput became a logistical challenge. While juggling virtual meetings with customers and suppliers and tracking potential quarantines, plant leaders found that successfully adapting to these constraints could position them for permanent reshoring opportunities. The answer, for many, was to expand robotics and automation.

“Customers who discovered the talent crunch or sought to improve cost and output found automation irresistible,” says Raul Scheller, managing director of robotics and automation at Sepro North America. “The pandemic accelerated a shift that moved us from ‘maybe we should consider automation’ to ‘we must implement it now.’”

This urgency spurred a surge in demand for robotics, prompting companies like Wittmann Battenfeld to post record sales in 2020 as clients revisited their automation strategies.

Trademark Plastics faced a dual challenge—short‑age skilled labor and operating with a reduced workforce during COVID‑19—prompting a significant increase in robotics and automation, with Wittmann Battenfeld as the chosen partner in 2020.

“Many firms that had been hesitant to invest heavily in automation found themselves compelled to do so in 2020,” observes Jason Long, national sales manager for robots at Wittmann Battenfeld. “The pace of adoption accelerated dramatically.”

This acceleration was echoed by numerous automation suppliers consulted by Plastics Technology. “We saw early signs that a lack of labor was pushing companies toward automation, and the pandemic amplified that trend,” notes Dino Caparco, engineering manager at Yushin America. “When demand surged, the feasibility of manual operations diminished, forcing a pivot to automation.”

“The pandemic underscored the resource imperative of automation,” says Jim Healy, VP of sales and marketing at Sepro. “It didn’t just reinforce the goal; it accelerated it.”

Healy adds that the urgency was far from a measured approach. “It wasn’t a ‘let’s explore this’ or ‘we’ll need it in six months’ mindset. It was ‘implement it now,’” he explains.

In 2020, the priority for many customers shifted from price to delivery time. “We had to guarantee inventory because customers were calling with tight timelines,” says Caparco at Yushin. “Lead time became the decisive factor.”

Robotics’ Record Results

Sepro and Yushin’s experience of immediate demand resonated across the industry. The Robotic Industries Association (RIA) reported that, “Despite the pandemic, robot orders in North America rose by 3.5 %.” In a year when many sectors contracted, automation grew in unprecedented ways. For the first time, sales to non‑automotive firms surpassed automotive orders. Life sciences orders climbed 69 %, food and consumer goods grew 56 %, and plastics and rubber increased 51 %. Automotive orders rose 39 %.

North America’s automation footprint also climbed, reaching a new global record of 113 units per 10,000 employees, according to the International Federation of Robotics (IFR). By region, Western Europe leads with 225 units, the Nordic countries 204, followed by North America at 153 and Southeast Asia at 119. The United States ranks ninth worldwide, behind Singapore, South Korea, Japan, Germany, and Sweden.

All suppliers cited a surge in demand. As of December 1, Wittmann Battenfeld’s U.S. division had already surpassed its annual record for robot sales, with a month remaining in 2020. VP of Sales Sonny Morneault projected sales of 550 robots by year‑end.

Sepro felt the 2020 downturn during the March lockdowns but rebounded as restrictions eased. “There was initial unease, but the last six months of the year were steady and growing, especially in the medical sector,” notes Healy. “We saw a dramatic uptick there.”

Caparco says 2020 was Yushin America’s busiest year, describing it as “dynamic” and “unexpectedly strong.” The pandemic influenced nearly every aspect of the business.

Reshoring Revitalized

The first COVID‑related supply‑chain shocks appeared in the U.S. before the first domestic case, as China’s lockdown in January 2020 forced many OEMs to re‑source domestically. “Reshoring began out of necessity for some,” explains Caparco. “With borders closed, companies had to find local suppliers for PPE and testing equipment, and that momentum is likely to continue.”

To sustain reshored operations, Scheller reports that many Sepro customers focused on boosting efficiency and cementing the case for domestic molding.

“Automation and robotics enable cost‑effective U.S. production,” Scheller notes. “I expect more companies to bring their supply chains back to North America.” He highlights packaging and consumer goods, such as cleaning supplies, as key reshored sectors. “Many brands that manufactured overseas have begun reshoring, while those already in America are re‑evaluating their competitiveness to keep production local.”

Focus on Flexible Automation

Given the fluid market of 2020, many adopters prioritized adaptable automation. Key to this was using controls that can be quickly reprogrammed as product runs change.

Healy emphasizes that Sepro’s controls “are powerful yet user‑friendly,” allowing operators to manage systems with minimal training, especially when supported by remote assistance.

Wittmann Battenfeld’s Wizard programming offers a video‑guided checklist. “Within 10–12 questions, the system generates the program for you,” says Long. “This wizard‑based approach is gaining traction.”

Caparco highlights the demand for flexible systems that can switch tasks with a single touch. “Our robots support complex automation projects and can be re‑programmed instantly for simple pick‑and‑place tasks,” he says. “Fixed, single‑product lines are giving way to adaptable solutions.”

Remote‑First Operations

The pandemic also accelerated the adoption of remote capabilities. “The ability to view and configure a robot program remotely is a game‑changer,” notes Long. “Historically, some customers resisted remote access, but the urgency of 2020 forced them to embrace it.”

Sepro’s Live Support and Yushin’s Yushin University program exemplify this shift, providing virtual training and installations. Caparco explains that virtual run‑throughs replace in‑person demos, offering the same insight with greater convenience and safety.

COVID‑19 Fades, Skills Gap Persists

As vaccines roll out and the pandemic subsides, the underlying demographic shift remains. Nearly 25 % of the manufacturing workforce is 55 or older, and by 2030, one‑in‑five Americans will be 65 or older. The median age of manufacturing workers rose from 40.5 in 2000 to 44.1 in 2018, compared with 39.3 and 42.2 for the overall labor force, respectively.

The Manufacturing Institute’s 2019 report warns that employers will face hiring shortages, higher wages, and an acceleration of robotics and AI to boost productivity. Automation is not a replacement for humans but a tool to alleviate capacity constraints.

Wittmann Battenfeld’s Long notes, “Our industry has always struggled to recruit talent, and COVID‑19 magnified that gap. We’re seeing companies adopt robots for tasks that don’t require a human touch, such as inspection or labeling.”

Healy adds, “Customers are constantly telling us they can’t find people. This universal challenge reinforces the case for automation.”