by Cassandra Balentine
Artificial intelligence (AI) enhances corrugated software through predictive analytics and machine learning algorithms.
While this is an area to watch, today, AI is mainly found behind the scenes to improve efficiency, accuracy, and decision making within workflow software. “Most applications focus on data-driven optimization, including demand forecasting, production scheduling, pricing guidance, and quality monitoring. AI helps to analyze historical and real-time data to identify patterns that would be difficult or time consuming for humans to uncover; enabling plants to reduce waste, improve throughput, and respond more quickly to changing customer needs,” shares Scott Anderson, senior product manager, Advantive.
Rather than replacing human expertise, Anderson attests that AI is typically embedded within ERP, MES, and scheduling systems to support better, faster decisions.
In today’s corrugated industry, AI has moved far beyond being a “futuristic buzzword.” It’s now a driving force behind modern ERP and MES platforms. “What used to be simple order tracking software has evolved into an intelligent engine that actively supports and enhances production performance. AI is reshaping how plants plan, operate, and make decisions,” notes Mariusz Sosnowski, CEO, HiFlow Solutions.
AI in a corrugated-focused environment delivers value across multiple areas including production planning and scheduling, material optimization, business and operational automation, and analytics,” adds Sosnowski.
Expected Growth
The adoption of AI in workflow, specifically corrugated software, is expected to expand significantly as data quality improves and integration across systems becomes more seamless. “In the future, we’ll see more predictive intelligence, where AI not only identifies issues but recommends solutions,” believes Anderson.
This includes more advanced demand sensing, automatic scheduling adjustments, smarter inventory management, and improved cost-to-serve analysis. “As the industry continues to face margin pressure, labor challenges, and increasing customization demands, AI will play a critical role in helping operations stay competitive and agile,” predicts Anderson.
Sosnowski stresses that AI’s role in the corrugated industry is poised for significant expansion. “Rather than a sudden revolution, we expect a steady, powerful evolution that will transform everyday workflows. Today, AI primarily supports teams with intelligent recommendations, but this is only the beginning. These capabilities will mature into semi-automated decision making and ultimately into fully automated, end-to-end processes that drive speed, accuracy, and operational excellence.”
Innovation will move in many directions. “One of the most exciting areas is the deeper integration of real-time sensor data—not just to trigger alerts, but to automatically initiate corrective actions at the exact moment they’re needed. As these technologies advance, AI won’t simply support operations; it will become a proactive engine that anticipates issues, enhances performance, and elevates the overall efficiency of corrugated production environments,” offers Sosnowski.
In a blog post Q&A: Corrugated Best Practice & the Role of Process Control, published by ePS Packaging, the company addresses the future of AI and automation in corrugated print environments. “In 20 years, AI-driven corrugators will likely be standard, but the key is ensuring the data feeding these systems is accurate. Poor AI can be worse than no AI,” states the post.
Mike Agness, VP of business development, Americas, Hybrid Software, feels that AI should be in every department in every company in the future. “Think of it as your basketball team’s ‘sixth man.’ It should be there with you to make your process more efficient. And, it should be trained to tie everything together, helping to make everything fast.”
Benefits and Limitations
Several areas of digital corrugated print production already utilize AI.
Leading producers leverage AI-powered tools to enhance every stage of the printing workflow, including prepress and automated file preparation, adaptive color management, real-time quality control, and predictive maintenance of inkjet printheads.
Anderson finds AI commonly applied to file preparation, color management, and quality control. “AI-driven tools optimize artwork for printability, detect potential defects before printing, and adjust color profiles dynamically to maintain consistency across short runs.”
AI is also increasingly used to analyze print data to reduce setup time, minimize material waste, and improve registration accuracy, which is important in high-mix, low-volume digital print environments that are common in corrugated packaging, adds Anderson.
For example, Hybrid Software deals mostly with graphic assets. “A component of graphic assets is also the structural data related to it. Some areas where AI is of great assistance is searching through all past jobs to see if a graphic fits any of the dies you may already have. Also, do you have any similar graphics to assure consistency? AI can also help to predict press performance—for example, the scheduled time to run a job, and predicting press issues or maintenance. AI is phenomenal for scheduling those algorithms,” says Agness.
While Sosnowski points out that the level of AI adoption in digital corrugated printing varies by organization, one thing is clear, “AI is rapidly becoming a key enabler of print quality, consistency, and efficiency. Especially given the unique challenges of printing on corrugated substrates. Uneven surfaces, variable material quality, and the prevalence of brown Kraft liners all demand smarter, more adaptive technology.”
Other areas of AI Agness sees specifically for digital print is analyzing the files to fine tune the RIP to get the press running its fastest. “We have the ability to read and interpret a file as it’s coming in, conduct ‘on the fly’ settings, and learn from the job to know what we need to do to rasterize the art most efficiently. Today’s technology and speed of hardware has become tremendous, but you still get those reasonably designed files with 58 million points that need to be optimized for output.”
Through these innovations, AI transforms digital corrugated printing from a traditionally challenging process into a more predictable, efficient, and high-quality production environment across many areas including prepress, color management, and maintenance.
Many parts of the corrugated print production process are candidates for AI. “I think AI will be used throughout all facets of many different projects as we continue to teach it new tasks. AI will continue to learn, but you have to instruct it throughout the entire process. It will be important for people to be involved because we still don’t get good files coming in from customers and designers. This is even true for digital print, which is typically less intricate than traditional print processes,” shares Agness.
Of course, while AI is a powerful tool, not every part of the workflow is a good candidate for this type of automation.
“Strategic decision making, critical thinking, customer relationship management, and creative design still rely heavily on human judgment, experience, and collaboration. Additionally, tasks that involve nuanced trade-offs, ethical considerations, or deep customer context are best handled by people,” comments Anderson.
Anderson feels that AI works best as an enabler, augmenting human expertise rather than replacing it. “It is meant to be a thought partner, not a thought leader. This is especially true in an industry where operational knowledge and customer trust are critical.”
Sosnowski agrees, noting that AI is excellent at supporting corrugated packaging printing workflows, but it should not replace human responsibility, creativity, craftsmanship, and relationship-based decision making.
Areas like final responsibility and sign-off decisions; final artwork approval; print run approval before going on press; physical machine intuition and craftsmanship; fine manual adjustments based on sound, smell, touch; emergency fixes during print runs; supplier and customer relationship management; and handling complaints and price negotiations, are not tasks ideal for AI, lists Sosnowski.
Expanding Reach
AI continues to expand its reach in automated print workflows. Corrugated is no exception.
Corrugated-focused workflow systems deliver value across multiple areas including production planning and scheduling, material optimization, business and operational automation, and analytics, providing insights that help improve quality, throughput, and profitability.
However, AI cannot replace human decision making in many instances.
Apr2026, Industrial Print Magazine
