While artificial intelligence (AI) has become one of the most frequently discussed topics in the food industry, its adoption in processing environments will likely progress more gradually compared to other sectors, such as packaging. 

The primary reason for this delay is risk tolerance, a major concern since processing environments face food safety implications, regulatory oversight, and product liability exposure, according to an upcoming report entitled Processing State of the Industry 2026. This report, developed in collaboration by PMMI, The Association for Packaging and Processing Technologies, and The Food Production Solutions Association (FPSA)), establishes a baseline view of the U.S. food and beverage processing machinery market.

In many current deployments, processing environments are leveraging structured data analytics and rule-enhanced automation rather than fully autonomous learning systems. For demanding operations, like meat and poultry processing, information is power, and data is particularly valuable when increasing complexity, rapid changeovers, and high-speed production require informed and agile decision-making. Consequently, data is rapidly becoming one of the most valuable assets in manufacturing, according to Data Management Standardization, a work product developed by the OpX Leadership Network, a group of senior consumer packaged goods professionals with 15+ years of experience, organized by PMMI. 

While full AI autonomy remains somewhat limited in processing, data-enabled systems are increasingly embedded in these environments, according to PMMI’s latest research. However, AI systems must meet higher reliability and accountability thresholds before widespread deployment. 

Consequently, rather than focusing on autonomous decision-making, today’s processing plants are leveraging:

• Machine monitoring — Continuous data capture systems that record operating parameters and event footage to identify faults in equipment components like camera sensors, which record pre- and post-event footage to identify faults upstream
• Inspection systems — AI-enhanced vision models testing where product variability or complex defect patterns challenge deterministic algorithms 
• Durability simulations — Internal lifecycle testing and durability simulation tools that model wear patterns, loading conditions, and the expected lifespan of components, collecting and analyzing large volumes of performance data, such as cycle counts, motion frequency, or load profiles, to validate designs and anticipate when components may require attention
• Knowledge transfer via human/machine interfaces — Large language model AI systems trained on machine documentation, service logs, and error-code libraries that translate technical alerts into plain language and provide step-by-step troubleshooting guidance 

Reliability, uptime and smart system design remain essential 

As meat and poultry processors work to increase output while meeting strict food safety requirements, original equipment manufacturers (OEMs) are shifting their focus to how automation and throughput optimization are being approached, the Processing State of the Industry 2026 report states. Rather than focusing solely on speed, processors and OEMs are increasingly prioritizing:

• reliability and uptime 
• data-driven maintenance strategies 
• faster cleaning and changeovers 
• simplified operation. 

In addition to an emphasis on machine reliability, increasing output remains the key motivator for new equipment purchases, reflecting the ongoing pressure for meat and poultry processors to scale production efficiently.

Food safety and sanitation requirements also continue to impact production efficiency, particularly in protein environments. For instance, PMMI study participants noted the complexity of cleaning processes depending on equipment design and product type, highlighting the need for more efficient sanitation solutions.

Labor constraints are also shaping equipment design and deployment, with a shift toward automation that reduces reliance on highly skilled operators while maintaining performance levels. 

For example, primary meat processing companies continue to face significant staffing challenges due to the physical strain and harsh environmental conditions associated with tasks such as de-hoofing, evisceration, quartering, and other slaughter-adjacent operations. These activities occur in cold, labor-intensive settings, which are increasingly difficult to staff. As a result, many of these processors are accelerating investment in specialized automation capable of taking on these physically demanding steps.

In the poultry category, the combination of strong consumer demand and persistent labor shortages is prompting a different type of automation. Although many primary operations remain labor-intensive, processors are increasingly targeting smaller, repetitive tasks that create bottlenecks when performed manually.

Another key trend shaping automation is the growing role of data collection and predictive maintenance and the subsequent shift toward systems that help prevent downtime before it occurs, supporting more consistent throughput.

When it comes to future automation usage, study participants identified integrated monitoring capabilities as a major opportunity for processors to maintain consistent performance without interrupting production.

Meat and poultry processors working to optimize production can explore the widest range of packaging and processing technologies in just a few days by attending PACK EXPO International 2026 (Oct. 18-21, McCormick Place, Chicago).

The event’s wide array of features and benefits can sharpen a brand’s strategic planning, market awareness, and decision-making. With professionals from 40+ industries under one roof, attendees can gain cross-sector insights, spot new market opportunities, and gain a competitive advantage.

All registered attendees can learn about new technologies, trends, and innovations shaping the future of the processing and packaging industries from 2,600+ exhibitors, while free educational sessions on the show floor present the latest breakthroughs, fresh approaches, best practices, and success stories. Plus, with targeted pavilions and curated planning tools, it’s easier than ever to find exactly what every operation needs.

Learn more about and register now for PACK EXPO International 2026, the largest, most comprehensive packaging and processing event in North America. Registration for the show is $30 until Sept. 25, after which it increases to $130.