A new report from research consultancy Smithers estimates the global packaging market at $1.2 trillion (£912 billion) in 2025 and identifies generative AI (GenAI) as a significant force driving growth, creativity, and operational efficiency across the industry.
The study outlines how AI is reshaping packaging design, production, and supply chain management, helping brands accelerate product launches, cut costs, and respond more quickly to changing consumer expectations.
“Every decade brings a new technology that reshapes the way we work – from the personal computer to the internet, mobile devices, and the cloud. Now it’s AI.,” said Josh Brooks, divisional director – packaging portfolio at Easyfairs, organiser of the Packaging Innovations & Empack event, which partners with Smithers. “Global investment in AI infrastructure is expected to reach $2 trillion (£1.52 trillion) in 2026, and the potential for packaging is immense. From creating personalised designs to optimising production lines, AI gives the industry the chance to rethink how we design, produce, and deliver packaging at scale.”
According to the report, GenAI is already lowering creative barriers by enabling personalised and virtual content, as well as generating packaging concepts on demand. Brands can develop products with greater certainty, supported by deeper insight into consumer preferences, while also reducing the time and expense typically associated with trial-and-error development, the report stated. Integration with digital printing, finishing equipment, automated forming systems, and intelligent packaging is expected to reshape supply chain operations and customer engagement.
The research notes that AI-driven technologies are also enhancing inventory management, operational efficiency, and waste reduction. In e-commerce, AI supports the creation of custom-sized packaging for individual orders. Robotics and collaborative robots are improving production-line adaptability, while predictive AI tools help manufacturers proactively manage operational risks, the research finds.
Other innovations highlighted in the report include “right-sizing” packaging to improve sustainability and reduce costs, rapid reconfiguration of machinery for complex shapes, and micro-fulfilment centres aimed at enabling around-the-clock delivery. Real-time data capabilities give manufacturers the ability to adjust instantly to shifts in demand, promotional activity, or weather patterns, while self-learning AI is viewed as a key component of future circular packaging systems.
The study also points to the rapid evolution of creative workflows. GenAI allows for bespoke graphics, faster prototyping, and large-scale customisation, with AI agents adapting designs based on market insights and consumer feedback. AI is being applied across text, code, images, video, and 3D content, and the report suggests these tools could outperform professional designers and developers by 2030 – representing a major shift in productivity and creative potential.
