Rob Penhallow - printconnect:
Welcome to printconnect, the podcast where we explore the technologies, trends, and ideas shaping the future of specialist printing.

In this episode, we're looking at a shift that's quietly gathering pace across the industry – the rise of robotics and how it's beginning to transform print production. From automated handling and finishing through to more integrated production environments, robotics is moving from a niche capability into something far more central to how print operations run.

At the same time, we're seeing increasing pressure from the packaging side, with brands demanding greater variation, faster turnaround times, and more agile production. That shift is accelerating the move towards digital print, but it also raises an important question – how do you scale that level of flexibility?

To explore that, I'm joined by Mark Boyt and Marc Mascara from Keypoint Intelligence. Welcome to the show, Mark and Marc.

Marc Mascara:
Thank you.

Mark Boyt:
It's great to be here.

Rob Penhallow - printconnect:
Brilliant. Before we begin, could you both introduce yourselves and tell us a little bit about what you do at Keypoint Intelligence?

Mark Boyt:
So yes, I’m Mark Boyt. I’m the Principal Analyst for Production Software and now also Robotics – that's the big growth opportunity.

My role at Keypoint is really to understand the pulse of what's happening in both of those spaces, see the changes in the market, and work very closely with our clients and vendors to help them take these solutions to market.

Marc Mascara:
I’m Marc Mascara, Principal Analyst for the Labels & Packaging Advisory Service.

Like Mark, the service deals with OEMs in the industry and helping them understand where the trends are and what’s changing in packaging.

I manage all four segments – folding carton, flexible packaging, labels, and corrugated – and we try to help our customers and guide them in the right direction of where the industry is going.

Rob Penhallow - printconnect:
Brilliant.

Starting with you, Mark – robotics in print isn't entirely new, but it feels like we're reaching a tipping point. From your perspective at Keypoint Intelligence, what's changed?

Mark Boyt:
Absolutely – robotics itself is not new. Robotics goes all the way back to the sixties when it first came into automation for the automotive industry.

And I guess it’s not new for printing either. There was a lot of robotics shown at drupa 2024 and that started to unveil the capability and opportunity robotics would bring.

But what's changed now is the reality of the pressures printers are under.

Year on year we ask the question, “What keeps you up at night?” and rising costs is always one of those things that comes back.

Then there’s labour. When we start to think about the challenges the industry faces – whether it’s ageing workforces, retaining people, or hiring the right people – that creates huge pressure on printers.

So I think those pressures are shifting printers from being conservative, as they have been in the past, to now really looking for solutions that will allow them to take future prosperity into their own control.

We’ve also seen the rise of AI. I think AI has opened people's minds to technology and the value it can bring. There are a lot of linkages between AI and robotics – the physical side.

But there are still barriers that need to be overcome.

That tipping point is being driven by need, but there are still things that, if not solved, will hold demand back.

What we're seeing today is robotics becoming more demand-led than supply-driven.

Rob Penhallow - printconnect:
Do you think the maturity of the technology now means it's becoming easier to integrate? Is that having an impact?

Mark Boyt:
Absolutely.

When you look outside the print industry and see what's happened in automotive and warehousing, you're seeing robotics really change the nature of those industries.

In some ways, you could argue that print is behind the curve and is now catching up.

The good news is that the robotic capability is already there.

What needs to happen is integration – integrated into the processes, integrated into the software, orchestrated and commanded correctly.

There’s also the challenge that print media is extremely varied and specific. Robots need to understand how to handle those materials.

And print puts more strain on variability, which robotics also has to learn to support.

Rob Penhallow - printconnect:
You recently completed an in-depth industry survey on robotics at Keypoint Intelligence. What were the standout findings?

Mark Boyt:
Probably the thing that jumped out first and foremost was the awareness and interest in robotics.

We did a survey last summer that indicated it was coming, but what surprised me with this one was the acceleration of anticipated demand.

When 70–80% of respondents say they’re interested in robotics, and around 40% say they’re likely to buy within one to three years, that indicates a very rapid surge.

I initially thought labour challenges would be the biggest driver.

But actually the number one reason given was automation and productivity – printers wanting to do more and be more effective.

At the same time, it still helps with labour shortages by allowing people to focus on their primary roles.

One concerning point was around who printers would talk to and buy from.

They would talk to press vendors and robotics companies – but when asked who they would actually buy from, the answer shifted heavily towards robotics companies.

The issue is that many robotics companies still don’t view print as a major opportunity compared to other industries.

So there’s potentially a gap in the market.

Will traditional print vendors expand into robotics? Or will robotics companies move into print?

That’s the big question.

Rob Penhallow - printconnect:
Marc, from a packaging perspective, we're seeing increasing pressure around shorter runs, faster turnaround times, and greater variation. How is that influencing the role of digital print? And where do you see the crossover with robotics?

Marc Mascara:
Packaging is very different from commercial print because it’s fundamentally a manufacturing process, and printing is only one part of that process.

When you look at packaging, you’re looking from the brand all the way down to logistics and shipping.

Why are we seeing this increase in SKUs?

I point to the rise of AI – not ChatGPT-style AI, but data-driven AI.

Brands own all the consumer and product data. They know what’s selling, where it’s selling, and what consumers want.

AI allows them to react much faster.

Maybe they skip one campaign and move straight into another because the data tells them it makes sense.

That creates more variation and more packaging versions.

The converters then have to deal with that explosion in SKUs and variation.

That’s extremely difficult for analogue print, but digital plays very well in that space.

On the robotics side, because packaging is a manufacturing process, you’re now seeing opportunities where printing can happen at different points in the line.

A robotic arm may move a carton past printheads before placing it on a pallet.

You can print last-minute information, codes, or variations directly during fulfilment or logistics.

That changes the manufacturing process significantly.

Adoption will be slow, but the larger converters and brands are already moving in that direction.

Rob Penhallow - printconnect:
So you've got digital increasing volume and complexity, and robotics looking to remove bottlenecks in things like handling and finishing, enabling scalable production. Is that how you see it as well, Mark?

Mark Boyt:
Definitely.

There are so many places where robots can add value across the process.

The challenge is understanding how to integrate all of those roles properly.

Rob Penhallow - printconnect:
What actually needs to happen for printers and converters to start realising these benefits at scale from where we stand now?

Mark Boyt:
Many printers are already very aware of robotics.

The bigger challenge is availability and supply.

At the moment, every robotics implementation in print tends to become a bespoke solution.

That creates complexity and cost.

What needs to happen is the productisation of robotics for print.

The press vendors are probably best positioned to understand the applications and work alongside robotics companies to create practical solutions.

Marc Mascara:
One challenge is that some commercial print OEMs are still approaching packaging with a commercial print mindset.

Packaging is a manufacturing process.

The native packaging manufacturers understand that process much better.

So there’s going to be a battle between traditional commercial print vendors entering packaging and the packaging-native manufacturers.

Rob Penhallow - printconnect:
You’re both involved with sessions at FESPA this year. Can you give us a sense of what those discussions will explore?

Mark Boyt:
I’ll be hosting a session on robotics with a really interesting panel.

Durst will represent the press side, Robot Factory will represent finishing automation, Cyan Tec will discuss industrial print applications, and LUNUS will focus on humanoid robotics.

We’ll explore where robots will add the most value, how they support people, and whether humanoid robots will eventually have a role in print.

Marc Mascara:
My session will focus on trends in packaging and the difference between specialty printing and mainline production.

The key discussion will be around how digital print expands into higher-volume packaging production.

Can ink costs come down? Can digital move further into the mainline?

That’s where the industry is heading.

Rob Penhallow - printconnect:
Looking ahead, how do you see robotics and digital print changing day-to-day production environments over the next few years?

Mark Boyt:
Robots are going to become much more common across the production floor.

Initially they’ll work alongside people, helping remove physical strain and repetitive tasks.

But longer term, their roles will expand.

I recently read about a robot in construction that wasn’t doing heavy lifting – it was observing and managing, using cameras and sensing technology.

You can imagine humanoid robots eventually doing similar things in production environments.

And eventually we’ll move toward more end-to-end automation.

Marc Mascara:
For digital printing, the real change is going to happen in workflow.

Packaging converters are still behind commercial print in workflow integration.

Some operations are still using sticky notes and paper.

As digital printing expands, workflow integration becomes critical.

Removing touchpoints throughout the manufacturing process is where the value comes from.

It’s not just about the digital press itself – it’s about removing silos across the entire process.

Mark Boyt:
Exactly.

Digital removed many silos apart from the manual handling side.

That’s where robotics comes in.

Rob Penhallow - printconnect:
Any final takeaways? Is there something you want listeners to leave with?

Mark Boyt:
There’s an inevitability about robotics coming into print.

The challenges around labour and rising costs are not going away.

Printers need to start those conversations now.

Even simple questions like: “Do I need space for robots in my production line in the future?” become important.

The future is coming.

The question is how fast and who’s ready.

Marc Mascara:
It’s not your father’s printing business anymore.

Technology is changing rapidly.

You may buy equipment today that could feel outdated in three or four years.

So my advice is: don’t get left behind.

Stay informed, follow the changes, and understand where the industry is heading.

Mark Boyt:
One final point.

Sometimes when you work within an industry, you only see what’s happening around you.

But what’s happening elsewhere matters too.

Take humanoid robots.

A year ago, humanoid robots running a half marathon took two and a half hours and only half finished.

A year later, they completed it in fifty minutes.

That’s the speed robotics is evolving.

And that capability will come into print.

Rob Penhallow - printconnect:
I think what really stands out from what you’re both saying is how quickly things are beginning to converge.

Digital print, robotics, and production workflows are no longer evolving in isolation, but starting to come together in a much more connected way.

And with that convergence comes pace.

These changes aren’t on the horizon anymore – they’re beginning to happen now.

So for printers, converters, and anyone involved in production, staying close to these developments is becoming increasingly important.

Mark Boyt:
And working out how to implement them into your own production line.

Rob Penhallow - printconnect:
Amazing.

Thank you, Marc Mascara and Mark Boyt.

Mark Boyt:
Thanks everyone.

Marc Mascara:
Thank you, sir. Glad to be here.

Rob Penhallow - printconnect:
Thanks again to Mark Boyt and Marc Mascara for joining us on printconnect.

One of the clearest takeaways from this discussion is that the future of print production is no longer being shaped by a single technology. Robotics, workflow automation, AI, digital print, and manufacturing integration are all beginning to influence one another in very practical ways.

And perhaps most importantly, these changes aren’t just relevant to the largest manufacturers or early adopters. As the technology matures and expectations around speed, flexibility, and efficiency continue to rise, these conversations are becoming increasingly relevant across the wider print industry.

As both Mark and Marc highlighted, the key now is staying informed, understanding where these technologies are heading, and thinking early about how they may fit into future production environments.

You can find more episodes, insights, and industry discussions at Specialist Printing Worldwide.

Thanks for listening, and we’ll see you next time on printconnect.