For many years, the concept of automation has sent many into a panic. Although these automated technologies have enormous potential, some are worried that too much reliance on automation could have dire effects on our economy and our workforce.
Most experts, however, stress that automated technologies aren't necessarily meant to replace human involvement. Instead, they're created to supplement what we already have while eliminating redundancies and preventable errors. We still need real people to complete a number of jobs – and to run and check these automation tasks. Automation simply creates efficiencies where they didn't exist before. And in many cases, automation can make for a safer experience.
That's certainly true within the pharmaceutical sector. Despite all sorts of stringent regulations surrounding the various types of pharmaceutical labels and pharmaceutical packaging that exist, medication errors can still occur. If and when they do, pharmaceutical companies risk fines, fees, recalls, and reputational damage. As such, it's crucial to prevent these kinds of mistakes before they ever have a chance to impact the general public. And, as many businesses operating in the pharmaceutical industry have already found, the solution to compliance, safety, and efficiency lies in automation.
In the context of pharmaceutical packaging, automation involves integrating intelligent systems that manage labeling, coding, inspection, and traceability without manual intervention. This approach supports both safety and compliance by creating a closed-loop process that continuously verifies product data. As regulations evolve, manufacturers turn to pharmaceutical packaging automation to meet strict requirements for accuracy and transparency while also balancing both compliance and productivity goals.
By combining precision engineering and advanced robotics, companies are adopting packaging automation and automated labeling as strategic solutions. These systems improve pharma packaging compliance while driving efficiency in pharmaceutical production, ultimately reducing errors in pharma labeling and improving patient safety.
In this post, we'll discuss some of the issues that can lead to pharmaceutical mislabeling and subsequent hazards like recalls and public safety risks. We'll then take a closer look at our increasing reliance on automation and how these technologies can significantly reduce or even eliminate risks.
In theory, we all know that accurate pharmaceutical labeling is important. But the reality is that mislabeled pharmaceutical products can have major consequences – both in terms of public safety and how your brand is perceived.
A report published by the Institute of Medicine found that pharmaceutical packaging and labeling issues served as the cause of 33% of all medication errors – and 30% of fatalities stemming from medication errors – in 2006. Although that report is from several years ago, it illustrates the essential nature of preventing medication errors from the start. And that comes down to what's included on your packaging and the types of pharmaceutical labels you use for your products.
When a mistake is included in pharmaceutical packaging or labeling, it can have devastating and far-reaching consequences. According to FDA data, approximately 19% of drug recalls between 2012 and 2023 were attributed to labeling issues. These errors can trigger steep fines, lost revenue, and long-term brand damage. Manual systems also slow production, creating bottlenecks and higher costs – challenges automation helps mitigate through precise verification and inspection.
Undeniably, one of the most critical consequences that can occur is compromising user safety. Patients need to trust that the medications they're taking will be administered correctly and that their labels reflect total accuracy. When different types of pharmaceutical labels contain even small errors, there's a likelihood that the product can and will be misused. This can result in unwanted symptoms or medication interactions for the patient; in more serious cases, it could even lead to hospitalization or even death.
Aside from the tragic loss of life, this possibility presents a huge problem for pharmaceutical companies. It's true that all drugs have possible side effects – but when those side effects are unintentional or the consumer isn't warned about them, this can raise issues associated with brand trust. A single adverse event related to a labeling or packaging error in medication can do significant and permanent harm to a brand. This is especially true when a product recall is made public. When you lose trust, you'll have to pour time, money, and energy into salvaging what remains of your reputation and earn back the respect of the people.
Of course, recalls also come with other pitfalls. Recalls come with major financial costs, which can be a huge burden for any pharmaceutical company to take on (especially if the product was released widely). You'll also incur financial repercussions due to time and resources lost as a result of the recall, as well as during the rectification process. And if the FDA or other regulatory agency learns that your packaging or the types of pharmaceutical labels you used weren't in compliance with pertinent regulations, you might experience further damage to your reputation and your business. Even if you don't voluntarily recall the product yourself, regulatory agencies like the FDA might do it for you. That can make it even harder for you to obtain approval in the future.
When the stakes are so high, it makes sense that those in the pharmaceutical industry would take every possible preventative step. Ultimately, embracing automation can be a way to safeguard the public and maintain product quality, compliance, and overall productivity.
You can learn more about the risks of poor pharmaceutical labeling.
The potential for mislabeling a pharmaceutical product is relatively high when you rely solely on humans to spot their own mistakes. Even if we consider ourselves to be detail-oriented, it's entirely possible for errors both large and small to slip by. When you're writing a school paper or drafting an email, those errors might not matter so much. But with pharmaceutical packaging and labeling, it can quickly become a literal life-and-death scenario.
That's why so many businesses operating within the pharmaceutical industry have embraced automation. According to PharmaceuticalProcessingWorld.com, an estimated 50% of all pharmaceutical recalls come down to errors in labeling or packaging artwork. Even the smallest details here – like missing information, content mistakes, malfunctioning barcodes, or misconstrued meanings – can result in delays, consumer safety risks, and potential product recalls.
To avoid these problems, careful inspection is required throughout each and every step of production. But with only human workers performing these tasks, problems can still slip through. And even if they don't, it takes far more time and effort for people to perform inspections with their eyes than it would for a computer to do the same with all its advanced capabilities.
Automation, when applied with great care, can provide the solution. When automated computer systems inspect different types of pharmaceutical labels, they can spot errors that aren't obvious to the naked eye (and can do so at a much more rapid speed and rate of accuracy). This allows pharmaceutical companies to perform more thorough checks at every stage of the manufacturing or distribution process. Rather than waiting until a product is on the shelf to be notified of an issue, they can catch the mistake before it ever goes to market. This can save time and money while preventing safety and reputational risks. With the help of these machines, pharmaceutical companies can avoid recalls and other concerns while ramping up efficiency.
Automation serves as both a corrective and transformative tool for modern pharmaceutical operations. By introducing digital precision and advanced verification systems, manufacturers gain the ability to produce safer, faster, and more compliant packaging at scale. The benefits extend far past risk reduction – automation drives measurable improvements in cost control, performance, and customer confidence.
Automated pharmaceutical labeling systems support FDA-compliant labeling and minimize risk by identifying inconsistencies early in the process. These systems strengthen pharma packaging compliance while maintaining complete documentation for audits and regulatory reviews.
Through advanced pharmaceutical labeling technology, automation eliminates repetitive manual tasks and streamlines production flow. This not only reduces waste but also drives measurable efficiency in pharmaceutical production and shortens time to market.
Built-in automated packaging inspection and data capture create a continuous record across every packaging line, offering traceability and accountability from batch to shipment. These records support faster resolutions and easier recall management when needed.
With smart robotics and automation in drug packaging, manufacturers can scale operations quickly while maintaining uniformity. Automated packaging systems allow pharmaceutical companies to expand production without compromising safety, accuracy, or compliance.
Automation is already reshaping how labeling and packaging are managed across different segments of the pharmaceutical industry. Each vertical presents unique regulatory and operational challenges, making automation essential for accuracy and compliance.
Clinical Trials: Automation simplifies global study management by maintaining precision across regions with compliant clinical trial labeling. It supports multi-language labeling consistency and reduces errors in complex trial supply chains.
OTC Products: OTC packaging solutions benefit from rapid production speeds and greater agility. Automated pharmaceutical labeling helps meet high-volume demand while protecting brand trust through consistent packaging presentation.
Medical Devices: Compliance with medical device labeling requirements demands advanced traceability and error prevention. Automated packaging systems detect inconsistencies in real time, reducing the risk of mislabeling and improving patient safety.
The pandemic has shown us just how important technology is to how we function. Automation quickly became essential for maintaining productivity, reducing costs, and building operational resilience when disruptions occurred. Flexibility and adaptability are now key to long-term success – and automation has become even more valuable as a result.
Today, the momentum continues well beyond COVID-19. Companies are embracing automation to strengthen supply chain visibility, improve quality control, and maintain regulatory compliance across global markets. By investing in digital-ready labeling and connected data systems, pharmaceutical manufacturers gain the agility to adapt faster, streamline production, and sustain compliance in real time.
Smart pharma packaging platforms are driving this evolution. These solutions merge automation with analytics to enhance traceability, minimize errors, and increase overall efficiency. As the industry advances, automation enables transparency and data-driven oversight, helping manufacturers meet rising regulatory expectations while accelerating delivery to market.
Consumers are also demanding greater clarity and trust in pharmaceutical packaging. Enhanced labeling systems and advanced formats now allow brands to communicate safety, dosage, and usage data with unmatched precision. What began as a pandemic necessity has evolved into a lasting commitment to accuracy, accountability, and public confidence.
If you haven't yet employed the use of automation in your packaging or labeling, now may be the time to consider making a change. To learn more about the types of pharmaceutical labels we can offer for your products or how we can support your goals of compliance and safety, please contact us today.
Contact PLPS for pharma packaging automation.
The next generation of automation is data-driven, sustainable, and intelligent. Technologies like machine learning, robotics, IoT, and the role of AI are shaping how organizations approach packaging precision and traceability. These innovations enable predictive error detection and support continuous improvement throughout production.
Emerging trends include:
PLPS is pioneering this next phase through forward-thinking design and sustainable innovation. Our Earth+ line reflects our commitment to combining automation and environmental responsibility, giving manufacturers access to smarter, greener labeling solutions. By integrating intelligent systems and connected networks, we’re creating packaging environments that enhance visibility, reduce waste, and optimize performance across every operation.
This innovation-driven approach positions PLPS as a trusted partner for clients preparing for the next evolution in automation and sustainability.
At PLPS, we combine decades of pharmaceutical expertise with cutting-edge technology to deliver packaging automation that meets the highest standards of compliance and performance. Our automated pharmaceutical packaging solutions enhance labeling precision, speed, and reliability, helping clients maintain quality across operations. With enterprise-level capacity and small-business responsiveness, we provide the agility and partnership that pharmaceutical brands rely on to stay compliant and competitive.
© 2024 Premium Label & Packaging Solutions | PLPS Sales Terms and Conditions
