Plastics manufacturers still need workers, both human and robotic

Labor availability, in plastics and in the manufacturing environment at large, is one of the biggest drivers for automation, he said, and the uncertainty in trade policy “adds another layer. When companies are unsure about sourcing or long-term cost exposure, many choose to automate to protect margins and build more resilience into their operations.”

Shikany expects automation demand in plastics to gradually improve over the next year. 

“This sector was one of the softer areas in our recent robot order reports ... and that reflects a real pullback in capital spending through 2024 and much of 2025. The overall direction of the market is still positive, though,” he said. 

While orders for the plastics industry have slowed, “the intent to invest is strong,” he said. “Most of the hesitation this past year came from timing and policy uncertainty, not from a lack of interest. As supply chains normalize and order pipelines firm up, we expect more projects to move forward.” 

Flexible work cells and integrated systems that bring robots, vision and inspection together are trending in the sector, along with collaborative applications, according to A3. (Reflecting that trend, Teradyne recently announced it will begin manufacturing Universal Robots collaborative robots in the U.S. in 2026 to meet growing demand.) 

“Processors are rethinking how people and automation work together and are looking for systems that reduce complexity and speed deployment,” Shikany said.  

OEMS ready to help implement automation 

Echoing Pineda’s observation, several equipment OEMs who discussed their outlooks for the coming year see opportunity in automation and other technologies to mitigate the labor situation. 

Peter Gardner, the outgoing president of LS Mtron Injection Molding Machine USA, said the move toward systems integration was a “clear takeaway” from the K show. 

“Customers increasingly expect machines to interface seamlessly with robots, vision systems and material-handling equipment. The expectation is no longer ‘automation-capable’ but fully integration-ready. A smart machine,” he said. 

While LS Mtron does not supply robots, the company’s IMMs support open communication protocols, standardized interfaces and controls that connect with any major robot, vision or auxiliary equipment provider. 

“Labor shortages continue to influence equipment decisions. Processors are prioritizing machines that deliver stable, consistent processes with fewer operator interventions and that integrate cleanly into automated work cells,” he said.  

Manuel Heusinger, Kautex’s VP of sales and service for the Americas, said the company is “addressing labor shortages and skill gaps by focusing on ease of operation, including simplified HMI screens and assistance systems that guide operators through key process steps.”  

Customers are seeking ease of operation, smart features and assistance systems that guide operators through tasks such as mold and tooling changeovers to address worker turnover, he said. 

“Making it easier to operate our machines is a core development and product effort at Arburg,” said Martin Baumann, president and CEO of Arburg Inc. “Our newly introduced Gestica Lite [controls] at the K show together with the new electric Allrounder Trend machine concept addresses exactly that issue by making the HMI very operator-friendly and easy to use.” 

Steven Rocheleau, president of Rocheleau Tool & Die, also sees customers using technology to compensate for the labor shortage, “whether that means greater automation or making equipment data more accessible through databases and monitoring systems to reduce defects, identify issues sooner and ultimately minimize downtime.” 

Wittmann, which builds robots and auxiliary equipment in addition to IMMs, is pursuing an aggressive strategy. 

“We are expanding our capabilities to support a significant increase in automation business and expanding into more complex systems. I’ve set a goal for our team to more than double our automation business over the next three years,” said Sonny Morneault, president of Wittmann USA.  

He said Wittmann is expanding its robot production capacity in the U.S. and has been seeking U.S.-made sources for robot components, including steel and aluminum beams, to avoid tariffs. 

Glenn Frohring, co-owner of Absolute Haitian, said he has seen automation sales increase over the past year. 

“Other years, customers might say, ‘Yeah, we really should automate this.’ But what's driving that now is just a lack of available people. And it’s like, ‘Hey, we’ve got to quit trying to fight this. ... Let’s just fully automate and move on down the road.’ Maybe it takes a little bit higher investment, but in the long run, it’s worth it. Robots don’t file workers’ comp claims. You don’t have to pay their health care,” he said. 

Automation has evolved past simple press-side takeout, and complex tasks are easier to accomplish with AI, he said. 

“Our machines all have AI features in the presses for teach[ing], programs for process assistance that reduce the setup time for our customers. It’s been very widely accepted and it’s been well-received,” Frohring said. “All those technologies allow our customers to get by with existing personnel. Instead of having 10 people that have to be dialed in and fully trained and understand, you might be able to get by with five on the same fleet of machines.” 

But AI hasn’t penetrated deeply into the industry yet. As Rocheleau said, “AI is a common topic of conversation, but practical, production-ready applications are still limited.” 

Or as Marko Koorneef, president of Boy Machines Inc., put it: “The focus is on AI, but nobody seems to be able to explain what that would be or should look like.” 

Morneault said he expected AI would have been more of a trend within the industry by now. 

“Of course, we know it’s coming. We have a lot of AI activity within Wittmann with the most prevalent being our AI product support help line and smart molding technology. Both have been in development for a few years now and are incredible tools,” he said. 

Pineda expects AI to fuel growth for the industry, and said OEMs need to embrace it to stay competitive. 

“If you’re selling equipment at the moment, part of the marketing statement is you’re selling something that’s going to be AI-ready... and I think you’d be missing the boat if you don’t use that to your advantage in terms of positioning your company, in terms of getting more customers, because everyone’s talking about AI. We don't know how it will play out in the end, but everyone’s excited about AI,” he said. 

Companies are integrating more Industry 4.0 and smart technologies into their equipment, but that doesn’t mean customers are using them yet. 

“Actual adoption varies widely by customer. Some use these features daily, while others have them available but not fully implemented,” Rocheleau said. 

Morneault echoed his observation. 

“Every IMM we sell has a level of 4.0 but the number of customers that are truly using the full package is still low; maybe 20 percent adoption. So, I would say only the early adopters are embracing it,” he said. “As we continue to develop new, even more user-friendly solutions, we expect this to go 100 percent.” 

Human workers still fill important roles 

While automation can handle many of the repetitive tasks of plastics processing, Pineda noted that it’s only part of the answer, “not really the magic bullet.”  

The Bureau of Labor Statistics reported a decline of about 4,900 jobs in plastics and rubber processing between November and December 2025, and a loss of about 7,400 jobs for the year. Pineda expects employment will continue to shrink in the sector, largely due to retirements. But human workers are still necessary, and processors might have to start paying more for them. 

“I think all processors would have to factor in higher costs of wages in 2026,” Pineda said. 

BLS data shows hourly earnings for production and non-supervisory roles rose from $25.20 in January 2025 to $26.20 in December. For all plastics and rubber employees, hourly earnings also went up in 2025, from $29.93 in January to $31.26 in December.

“The industry will need to be used to getting workers at a higher rate than before, and in fact, a lot of the supply [of workers] would probably come from companies that have downsized... because of mergers and acquisitions and all the reorganizations,” he said. 

Competition for those skilled workers will be fierce: “The key is to be quick, so that your competitors don’t get to those workers before you can,” Pineda said. 

On the other hand, Laurie Harbour, a partner at Wipfli and longtime consultant to manufacturers, thinks many companies, spooked by the difficulties of hiring in 2022 and 2023, have held onto workers they don’t need as business has slowed and the labor market has cooled. 

“Our data says that two-thirds of people are expecting revenue to be flat or down, profits to be flat or down, but 82 percent of them are hiring for growth or staying flat. The math doesn’t work. We’re not right-sizing,” she said. 

Harbour said proper applications of automation can help processors adjust their staffing to meet current production requirements, so they can let “C players” go and hire more skilled personnel when business volume returns. 

Processors and OEMs continue to explore ways to increase those skill levels.  

Heusinger said Kautex offers “multiple levels of operator training, including our Virtual Trainer, a flight-simulator-style training tool for blow molding.”  

Morneault said Wittmann has several partnerships with tech schools that help “create a constant flow of talent being funneled into plastics,” including internships, on-the-job training and Wittmann Academy, which brings in graduate-level engineers to spend a year learning about multiple areas of the business. 

“We’ve seen several of our customers doing the same thing to help them with labor shortages,” he said.  

Frohring also noted increasing interest in trade schools and said plastics programs at colleges such as Ferris State and Penn State Behrend are preparing for higher enrollment. Haitian’s instructors and training classes are also seeing higher attendance.  

“I think no matter who you talk to, there’s always going to be a workforce challenge. We definitely see some areas of tightness,” said Larry Hovish, director of communications for injection molder Mack Molding. 

His company has an internship program that has added “well over 30” entry-level full-timers to the staff over the past decade, and Mack has also been investing in training, leadership and workforce engagement efforts. 

“You want to do things that will shore up the people that you do have, because I think most people would tell you that it costs more to replace somebody than to keep them. So, we want to give people the skills that they need to be successful, but also make them want to stay here,” he said. 

Ken Parker, CEO of injection molder Tech-Way Industries, said his company has an internal training program for operators, inspection personnel, setup personnel and others, as it can’t always find qualified personnel from outside sources.  

“At the same time, if we can train them internally, we have contributed to society, by creating a better workforce for the future,” he said.