Originally Published October 23, 2019 9:00 am UTC+0
What Changed Since We First Looked at Automation Trends
Editor’s Update: This article was originally published in 2019 to look ahead at industrial automation trends for 2020. It has been updated to reflect what actually happened, what changed across manufacturing, and where robotics and automation are heading next.
When ROI Industries first looked at the top industrial automation trends shaping 2020, many of those ideas were still emerging. Today, they are part of the daily conversation in manufacturing, logistics, packaging, maintenance, and material handling.
The biggest change is not only the technology. It is the urgency behind it.
Manufacturers now face tighter labor markets, higher expectations for uptime, more demand for flexibility, and stronger pressure to improve efficiency without adding unnecessary complexity. As a result, automation is no longer viewed as a future upgrade. For many operations, it is now part of staying competitive.
ROI Industries sees that shift nearly every day. Companies are not just asking what technology is available. They are asking what solution fits their workflow, space, labor needs, and long-term production goals.
The Trends That Moved From Emerging to Essential
Several automation trends identified in the original article did not fade. They grew stronger, faster, and more practical.
Industrial Internet of Things (IIoT)
The Industrial Internet of Things has become a core part of smart manufacturing. Connected machines, sensors, controllers, and software now help operations track performance, identify issues, and make better decisions with real production data.
Instead of waiting for equipment to fail or relying only on manual reporting, more facilities can now monitor conditions in real time. This supports better maintenance planning, stronger quality control, and improved uptime.
Industry 4.0 and Connected Manufacturing
Industry 4.0 is no longer just a buzzword. It is the foundation for connected manufacturing environments where equipment, data, and people work together more effectively.
For manufacturers, this means better visibility across production lines, stronger coordination between systems, and more informed decision-making at every level of the operation.
Edge Devices and Real-Time Data
Edge devices have become more important as manufacturers depend on faster data processing near the machine. This helps reduce delays and supports real-time decisions for robotics, machine vision, inspection, and automated controls.
As AI becomes more practical in manufacturing, edge computing will continue to play a larger role. Data needs to be processed quickly, close to the equipment, and in ways that support safe, dependable operation.
Industrial Robots and Collaborative Robots
Robots have moved deeper into everyday manufacturing. Global demand for factory robots has more than doubled over the past decade, with 542,000 industrial robots installed worldwide in 2024, according to the International Federation of Robotics.
This growth reflects a clear shift. Robotics is no longer limited to large enterprise operations. Smaller and mid-sized manufacturers are also adopting robots, cobots, palletizing systems, and automated handling equipment to reduce strain, increase consistency, and support production goals.
ROI Industries supports that shift with systems like the STACKBOT mobile collaborative palletizer and STACKMAX palletizing systems, each designed to solve real end-of-line automation challenges.
Industrial Cybersecurity
As more machines and systems connect to networks, cybersecurity has become a critical manufacturing issue. A connected factory creates new opportunities for productivity, but it also creates new risks.
Modern automation planning now needs to include secure access, system monitoring, software updates, and vendor coordination. For manufacturers, cybersecurity is no longer only an IT concern. It is part of protecting uptime, production data, and operational continuity.
What Is Driving Automation Now
Since 2020, the conversation around industrial automation has become more practical. Companies are less interested in technology for its own sake. They want solutions that solve immediate problems.
Labor Pressure and Workforce Support
Automation is often discussed as a labor replacement tool, but in real operations, it is often about workforce support.
Repetitive lifting, awkward motion, and manual palletizing can create strain and injury risk. Robotic palletizers, conveyors, pallet dispensers, and end-of-arm tooling can help reduce those demands while allowing employees to focus on higher-value work.
This matters for retention, safety, and productivity. When equipment supports people instead of overloading them, the whole operation benefits.
Flexible Automation
Manufacturers are moving away from rigid, oversized automation systems when a smaller, more adaptable solution can do the job. Flexible automation is especially important for facilities that run multiple products, manage seasonal demand, or need to reconfigure lines over time.
Mobile and compact palletizing systems are part of this shift. Instead of locking every operation into a fixed cell, manufacturers can use flexible automation systems that fit the floor, the load, and the pace of production.
AI in Manufacturing
AI is becoming more useful in manufacturing, especially in areas like predictive maintenance, machine vision, inspection, robotics, and process optimization. The most practical applications are not science fiction. They are tools that help operators find problems earlier, improve consistency, and reduce avoidable downtime.
The National Institute of Standards and Technology provides valuable insight into the future of AI, robotics, and intelligent manufacturing systems. That reinforces what many facilities are already seeing: smarter systems need better data and more reliable deployment methods.
End-of-Line Automation
End-of-line automation continues to grow because it solves one of the most common production problems: moving, stacking, wrapping, and handling finished goods efficiently.
For many companies, the right improvement is not a full-facility redesign. It may start with a smarter palletizing system, better conveyor flow, a pallet dispenser, or custom end-of-arm tooling designed for the actual product being handled.
Where Automation Is Going Next
The next phase of automation will be defined by practical intelligence, not unnecessary complexity.
Manufacturers will continue looking for systems that are easier to deploy, easier to support, and better matched to real production environments. This includes:
- AI-assisted robotics
- Predictive maintenance tools
- Flexible palletizing systems
- Smarter conveyors and transfer systems
- Better integration between people, machines, and data
- Stronger cybersecurity for connected equipment
The companies that benefit most will be the ones that start with the right question: what does this operation actually need?
That is why ROI Industries begins with the system, not just the machine. The goal is to understand the workflow first, then recommend the right automation path.
Take Advantage of the Next Phase of Industrial Automation
Industrial automation has changed a great deal since this article was first published. Yet one thing has stayed the same: the right solution depends on the real needs of the operation.
Whether you are evaluating palletizing, robotic integration, conveyors, PowerStand equipment, or a broader automation strategy, ROI Industries helps identify the right equipment for the job.
Explore STACKBOT, STACKMAX, PowerStand, and EOAT solutions, or contact ROI Industries to start with a practical system review.
Additional Automation Resources
To learn more about global robotics adoption and manufacturing automation trends, visit the International Federation of Robotics, one of the leading resources for industrial robotics data and reporting.
For additional ROI Industries solutions, explore:
- STACKBOT Mobile Collaborative Palletizer
- STACKMAX Palletizing Systems
- PowerStand Engine Positioning Equipment
- Custom EOAT Solutions
- Machinery & Automation Systems
- Request a System Review
Follow ROI Industries on LinkedIn for updates on automation systems, robotics, workflow improvements, and industrial innovation.
Original post from 2019
Manufacturing Trends 2020 Has in Store
The Industrial Internet of Things (IIoT)
Cut automation costs and improve your ability to scale with a higher performance processor.
The Industrial Internet of Things is an interconnected web of devices and processes that helps create a modern “smart factory.” This intuitive set of tools makes project management a breeze.
Some of its essential functions include analytics software, cloud computing capabilities, and ultra-precise sensory equipment.
Industry 4.0 Open Architecture
Automation in manufacturing industries is often tied to industry 4.0 technology. This high-quality form of automation integrates cyber-physical systems into your manufacturing operations. Industry 4.0 coordinates data exchanges between manufacturing lines, enterprise systems, and robots. Users gain a closeup view of different labor forces, which simplifies the process of vendor management. This gives vendors an edge to distinguish themselves in the marketplace.
Edge Devices
An edge device is a byproduct of the IIoT. This high-tech solution improves the performance of data at each entry point. Essentially, an edge device is a suite of monitors and sensors that serves as a gateway for real-time data adjustments. To put it simply, this intelligent technology bundle is responsible for communicating vital information between servers, enterprise systems, and other mobile devices tied into your network.
Industrial Robots
A booming trend in the manufacturing industry is collaborative robot intelligence. Today, more and more manufacturing operations are adopting robot technology to streamline labor-intensive projects. With lower costs and a more diverse line of applications, these robots follow in the footsteps of the personal computer by delivering size, power, and convenience to a broader community of small manufacturers.
Dedicated Communication Channels
Today’s current industrial automation circumvents the way we relay information throughout different stages of the operation. Communication is more fluid and efficient across multiple sectors of the operation. Automation technology categorizes and transmits data in three different tiers:
- The Cell/Area Zone: Processing data, information that’s controlled by the first level of management, and details handled by the area’s supervising units
- Manufacturing Zone: Data pertaining to the site manufacturing unit
- Enterprise Zone: Data that is converted into usable forms and transferred across servers, workstations, and other databases not linked to the operation site
Multi-Touch Control Devices
The industrial industry is dominated by the power of mobility, and powerful open platforms are starting to make waves with multiple manufacturing companies. This new interactive hardware is quick to install and extremely user friendly. Its wireless design is adaptable to any workplace environment. This helps operations save big on costs, time, labor, and maintenance.
Portable Applications and Mobile Apps
Nonportable applications are a dying paradigm. The importance of mobility cannot be understated, and it is a vital component of industrial automation technology. Mobile apps give engineering professionals a fast and user-friendly way to access plant information with just the press of a button. This gives project managers the ability to manage data and perform important tasks whether they are in the office or out in the field.
Open Process Automation Forums
Established by The Open Group, the Open Process Automation Forum focuses on developing a standards-based, open, secure, and interoperable process control architecture. Today, industry professionals increasingly rely on this open forum as a fast and reliable way to secure architecture information from end-users and suppliers in industries that include:
- Food and beverage
- Mining and metals
- Oil and gas
- Petrochemicals
- Pharmaceuticals
Industrial Cybersecurity Management
Many manufacturing operations have become easy targets for cyberattacks. This calls for extra layers of cybersecurity. Advances in cybersecurity help protect sensitive data from getting into the wrong hands. Because these functions are automated in your network, it eliminates vulnerabilities from triggering operation-related risks when data is transmitted through different stages of the project.
Virtualization
Increased functionality allows software-centric operations to operate on fewer platforms. This gives project managers the ability to consolidate data on one device. This all-encompassing solution makes it easy for operators to function more efficiently.
Take Advantage of the Next Frontier of Industrial Automation
When it comes to machinery and automation, ROI Industries is today’s gold standard. We are experts who identify customer requirements and address them with the appropriate solutions. With the ROI Industries team in your corner, expect premium quality equipment to match the pace of your industry.
Contact us today to schedule a free consultation with our team of problem solvers.
