New Report: Finding Skilled Workers Remains a Challenge
A new PMMI survey shows most CPG companies face persistent labor shortages, with growing pressure to modernize training and automation strategies
About 95% of consumer packaged goods (CPG) companies say they are struggling to hire skilled operators and technicians. And nearly 60% expect hiring issues to become somewhat or more demanding in the future, according to a recent survey conducted by PMMI, The Association for Packaging and Processing Technologies.
The research report titled 2025 Inside the Workforce Gap also noted that training and knowledge-retention issues must be addressed.
Many CPG companies believe operators learn best by doing, so they primarily rely on shadowing and hands-on repetition for training. But these approaches carry risks because training can vary by shift, and knowledge is lost when experienced staff leave, according to PMMI.
“The CPG firms interviewed said the labor problem is exacerbated by the retirement of experienced staff, high turnover among new hires, and intense competition for technicians, leaving many companies unsure how the labor pool will improve,” says Jorge Izquierdo, vice president, market development at PMMI.
When it comes to training new staff, printed materials and employee shadowing are currently the most widely used methods. Currently, digital and embedded tools are underutilized.
However, many end users see automation as a solution to workforce challenges and plan to concentrate its use on loading/unloading, inspection, and changeover operations, despite barriers to its implementation, including return on investment (ROI), small plant footprints, and potential downtime due to installation and training.
OEMs play a role
When PMMI researchers asked original equipment manufacturers (OEMs) how often their customers discuss workforce challenges with them, nearly two-thirds said they do so often or always.
Consequently, OEMs that modernize equipment design and training/support models will be best positioned to help close workforce gaps and meet evolving customer expectations. In addition, educating end users on underutilized tools and demonstrating ROI on training investments can drive stronger adoption of automation.
But OEMs must do more than that, researchers found. Currently, end users report that sophisticated machines can be difficult to troubleshoot and maintain in real-world conditions. Additionally, operators frequently struggle with complex or customized machines, outdated manuals, and the lack of built-in guidance.
In fact, only 14% of CPG respondents rank printed standard operating procedures (SOPs) or manuals as the most effective method for onboarding or upskilling operators.
CPG companies are requesting more training by video content, which many view as a flexible, accessible format that could support operators on demand—signaling an opportunity for OEMs to expand their offerings.
End users also believe that scalable complements, such as short training videos or picture-driven manuals, could help capture expertise and reduce dependence on undocumented knowledge.
In addition, to reduce risk and improve training outcomes, companies may need to pair hands-on shadowing with documented, digital formats that make knowledge more consistent and transferable across the workforce.
OEMs can bridge the gap by implementing practical design features and embedded tools that can reduce errors, cut downtime, and empower less experienced staff. Machine builders should also provide training tools that are clear, consistent, and accessible, including multilingual, picture-driven manuals; short, task-based videos; and digital libraries linked to each machine. Training could also be improved through skilled trainers and follow-up support after installation, according to PMMI.
