Packaging Trends from Pack Expo 2025: Sustainability, Data-Backed Decisions and Automation Remain Top Themes

Pregis was pleased to attend the 30th anniversary of Pack Expo Las Vegas. The show hosted record-breaking attendance, with over 2,300 exhibitors and more than 1 million square feet of innovation. From automation breakthroughs to sustainability milestones, the show spotlighted the future of packaging across industries like food and beverage, retail, automotive, healthcare, and beyond. For packaging distributors, manufacturers, and brands, the trends unveiled at this year’s show offer a roadmap to smarter operations and stronger customer connections.

1. Automation That Adapts

Labor shortages and rising operational costs continue to  push automation to the forefront. Exhibitors showcased modular systems, autonomous mobile robots (AMRs), and servo-driven machinery designed to handle variable packaging formats with minimal downtime. These technologies are no longer just about speed, they’re about flexibility. 

Action: Companies should explore automation solutions that can scale with SKU complexity and seasonal demand. Modular and adaptable systems can help reduce labor dependency while improving throughput and consistency.

2. Sustainability as Strategy

Sustainability was more than a buzzword – it was a movement. From curbside and store drop-off recyclability to post-consumer recycled (PCR) materials and compostability, the show emphasized packaging’s role in circular economies. PMMI’s Material Transitioning Dashboard revealed a shift away from polystyrene and PVC toward recyclable fibers and flexible solutions with PCR.

Action: There are a growing number of sustainable levers gaining steam in the marketplace, and businesses shouldn’t invest in them all. Instead, companies must pick an environmental path tailored to their unique needs and ensure timely alignment with regulatory shifts (e.g., extended producer responsibility).

3. Smarter Packaging Formats

Efficiency gains are coming from format shift – think mailers replacing boxes, flexible pouches over rigid containers, and right-sized packaging to reduce dimensional weight. These changes optimize the packaging value chain from fulfillment to shelf.

Action: Rethinking packaging formats can reduce shipping costs, minimize waste, and enhance customer experience. Companies should evaluate their current packaging mix and identify opportunities for format optimization.

4. Digital Integration for Real-Time Visibility

Connected packaging systems were a major theme at Pack Expo 2025. IoT-enabled sensors, cloud-based dashboards, and predictive analytics tools are now being integrated into packaging lines to monitor performance in real time. These solutions help reduce downtime, improve quality control, and enable proactive maintenance.

Action: Companies should lean more heavily into digital tools that integrate with existing ERP or WMS systems to gain actionable insights on throughput, waste, and equipment health. This visibility can drive smarter decisions and reduce costly disruptions.

5. Personalization and Brand Experience

Beyond protection, packaging is becoming a strategic brand touchpoint. Advances in digital printing allow brands to personalize packaging at scale – whether through QR codes, localized messaging, or seasonal graphics. This trend aligns with consumer demand for unique, engaging experiences.

Action: Brands should explore how packaging can serve as a marketing channel. Incorporating interactive elements or personalized designs can strengthen customer loyalty and differentiate products in crowded markets.

For more information on Pack Expo and how Pregis solutions and services can help, click here.