The Real Cost of Ownership: Protecting the Longevity of End-of-Line Systems in 2025

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As UK food manufacturers navigate economic uncertainties and shifting market dynamics, Endoline Robotics underscores the critical need to maximise the returns from existing automation investments through a robust Total Cost of Ownership (TCO) strategy. With capital expenditure under scrutiny, manufacturers must look beyond the initial purchase price and consider the long-term value of their automation assets.

Driving Productivity in a Demanding Market

While many OEMs promote their systems’ ability to enhance performance, boost efficiency, and increase output, the discussion must also focus on minimising TCO to unlock hidden savings and prevent costly downtime. The fast-paced FMCG sector demands that manufacturers do more with less—driving down costs, eliminating waste, and enhancing productivity while meeting market demands with precision.

A key advantage of robotics is the significant productivity boost they provide. Robots can deliver up to 30% more output than human labour, operating consistently and without fatigue. This increased output allows manufacturers to meet higher production demands with fewer resources. Importantly, this shift also enables human workers to focus on higher-value, strategic roles within the business—areas where creativity, decision-making, and flexibility are essential.

Maximising Long-Term Value Through Maintenance

Ensuring that automation equipment operates at peak performance is essential for maintaining production efficiency, worker safety, and product quality. Equipment failures often stem from neglected service intervals or the use of non-OEM-approved replacement parts. Maintenance should not be viewed as a routine expense but as a strategic initiative integral to a company’s overall business plan.

Manufacturers should seek automation solutions that not only improve efficiency and output but also reduce the long-term TCO of their robotic systems. The key to maximising this lies in proactive maintenance, strategic servicing, and leveraging the expertise of the OEM who designed and installed the system.

Unscheduled downtime can be costly, and attempting to cut corners by employing non-specialist engineers may result in improper servicing, voiding warranties and causing further operational disruptions. Implementing a scheduled OEM-approved service plan ensures that equipment continues to run smoothly, with minimal risk of unexpected failures. OEM engineers bring in-depth knowledge of their systems, allowing them to identify potential issues before they escalate. Whether it is detecting early signs of bearing wear or adjusting air pressure for optimal performance, their expertise can extend the lifespan of robotic systems while improving efficiency. Moreover, as robotic technology evolves, OEM engineers can recommend retrofits and upgrades that enhance flexibility, increase speed, and improve overall system performance.

Building In-House Expertise

Another critical factor in reducing TCO is investing in training for in-house engineering teams. Many large food manufacturers assume their engineers lack the expertise to maintain and operate sophisticated robotic systems. However, partnering with OEMs for hands-on training enables these teams to develop the necessary skills to handle regular servicing confidently.

When engineers understand the intricacies of their machinery, they can proactively prevent issues, reducing the reliance on external support and lowering maintenance costs in the long term.

Spare Parts and Smart Investments

Stocking essential spare parts is another crucial aspect of minimising downtime. Critical components, such as tape heads, must be readily available to ensure seamless operations. Unexpected breakdowns can disrupt entire production lines, leading to financial losses and missed deadlines. By maintaining an inventory of high-wear components, manufacturers can swiftly address minor issues before they escalate into major operational setbacks.

Investing in high-quality robotics from the outset is also a decisive factor in optimising long-term costs. While cheaper alternatives may seem attractive in the short term, the cumulative expense of frequent replacements and repairs often exceeds the cost of investing in a superior, well-built system. A long-term perspective ensures that quality automation solutions deliver sustained efficiency, reliability, and cost-effectiveness over the machine’s lifecycle.

Future-Proofing Through TCO Strategy

As the UK continues to invest in automation, ensuring that existing capital equipment is maintained effectively during periods of economic uncertainty is more important than ever. With careful planning, Total Cost of Ownership can be kept to a minimum and, if strategically implemented, enable businesses to increase both productivity and efficiency.

With automation continuing to reshape the UK’s manufacturing landscape, ensuring the longevity and efficiency of robotic systems has never been more critical. The Total Cost of Ownership for robotics extends beyond the purchase price, encompassing maintenance, energy consumption, and spare parts. By carefully planning and implementing a strategic TCO approach, manufacturers can maintain operational efficiency, increase productivity, and future-proof their investment in robotics. In a competitive market, those who prioritise the longevity of their automation assets will be best positioned to thrive in 2025 and beyond.

By Suraj Patel, Sales Manager, Endoline Robotics

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Unlocking Growth Through Automation: Saving Space with Robotic Systems

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The UK food and drink manufacturing sector is at a pivotal moment. With the potential for a £14 billion growth opportunity, as highlighted in the recent Food and Drink Federation (FDF) report, it’s evident that investment in technology, data, and skills is crucial to unlocking this potential.

Yet, despite a doubling of investment over the past two decades, the industry faces systemic barriers to growth. Among these obstacles are the challenges associated with adopting automation and robotics, including perceived inflexibility, floor space constraints, and the pressure for rapid return on investment (ROI).

Overcoming Space Constraints

At Endoline Robotics, we are aware that many food and drink manufacturers operate in environments where floor space is often small and a valuable commodity. These constraints often lead to hesitance in integrating robotic systems due to misconceptions around the physical footprint and adaptability of the equipment. However, modern robotic solutions have evolved far beyond the bulky and rigid systems of the past.

One of the most significant benefits of robotic systems lies in their ability to optimise factory layouts and maximise space efficiency. Robots can be mounted in multiple configurations, enabling them to work effectively in confined areas without compromising overall productivity. Beyond their productivity-enhancing capabilities, robotic systems also account for critical health and safety considerations. Designed with careful planning, they ensure that manual staff can operate in tandem with machines in a safe and efficient environment, maintaining high standards of safety.

Improved Productivity with Robotic Efficiency

Adding robots to a production line also means utilising their ability to operate continuously. Unlike human workers who require breaks and shifts, robots can run 24/7, significantly increasing output, consistency, and reliability. For repetitive tasks like palletising or case packing, robots not only outperform human counterparts in speed and precision but also reduce errors, leading to higher-quality results. These advantages ensure a faster ROI, offsetting initial hesitations about cost.

Adapting to Demand with Flexible Robotic Systems      

Another challenge manufacturers face is the growing demand for production flexibility. Retailers now push for faster turnarounds and greater variations in their offerings, requiring manufacturers to maintain agility. Robotic solutions can seamlessly switch between different processes through programming which offers manufacturers unparalleled flexibility.

Whether it’s adapting to product changes or responding to customer demand for greater output, robotic solutions can achieve this with minimal disruption to existing operations.

Robotic systems meet these demands, delivering both reliability and versatility. Intelligent factory designs, paired with the right robotic solutions, allow for efficient manufacturing flows while future-proofing operations for emerging demands.

Taking a Customised Approach

At Endoline Robotics we understand the complex needs of the food and drink industry. Our in-house capabilities allow us to design, construct, and integrate versatile, high-quality end-of-line automation systems, from robotic palletising to case packing. Every solution is customised to fit specific manufacturing requirements, ensuring that each client maximises both their physical space and their efficiency while enabling them to thrive in this competitive landscape.

Reflecting on 2024 and the Road Ahead for UK Manufacturing

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As 2024 draws to a close, it’s important to take a moment to reflect on the successes and challenges of the past year while looking ahead to opportunities for growth in 2025. At Endoline Automation, it has been a landmark year for us in many ways. We’ve been fortunate to complete significant projects for both new and long-standing clients, and our ongoing efforts to innovate and adapt our systems have culminated in some truly proud moments.

One highlight this year was the PPMA Show in September, where we launched our Pack for the Future theme. This concept resonated deeply with our ethos as a business—helping manufacturers adjust to evolving packaging trends over the last four decades while reflecting our commitment to staying at the forefront of end of line machinery innovation and ensuring that our clients are always a step ahead in their markets.

We were also thrilled to win an Automate UK Award for our pioneering 407 High-Speed Random Case Gluer. This fully automated top and bottom random case gluer represents the kind of tailored solutions that drive value for manufacturers. Designed for a globally recognised confectioner in Australia, this project showcased our technical expertise and expanding international presence. Over the past year, strengthening relationships with distributors has allowed us to extend our reach into new territories—a testament to the growing recognition of our work beyond UK shores.

Yet, while we celebrate these accomplishments, there’s a sobering reality closer to home. The global manufacturing market is racing ahead, with international adoption of automation and robotics increasing exponentially. The UK, however, has not kept pace. Make UK’s report that the UK has fallen out of the top 10 manufacturing economies underscores the urgency of this issue. While UK manufacturing hasn’t necessarily shrunk, other nations are accelerating their growth, largely through investments in automation and technology.

If the UK is to regain its position as a leading manufacturing economy, we must collectively commit to adopting automation at a scale that matches our competitors. Automation isn’t just about machines replacing manual labour; it’s about enhancing productivity, streamlining operations, and creating a competitive edge. Automated and robotic systems not only ensure consistent quality and production rates but also reduce waste and inefficiencies —key components for businesses looking to stay profitable, competitive, and sustainable.

The anticipated labour shortages have undeniably materialised. According to recent reports, there are currently 61,000 manufacturing vacancies, which add up to a staggering £6bn in lost opportunities. Global instability is further driving interest in reshoring manufacturing to the UK. To capitalise on these factors, businesses must begin to see automation not as an option but as a necessity.

The skills gap is often cited as a barrier to automation adoption. While it’s true that implementing and running automated systems requires expertise, this should not deter investment. Companies must focus on upskilling their workforce to manage these technologies while enabling their employees to focus on tasks that require human ingenuity and decision-making. Automation specialists such as Endoline, will also support the upskilling to ensure that the systems run seamlessly, while offering ongoing assistance to ensure the longevity of our machines.

Smaller businesses, in particular, may hesitate to adopt automation due to concerns about cost or fears that systems will become redundant as business needs evolve. These are valid concerns, but they are largely misconceptions. Today’s automation technology is designed with flexibility in mind. At Endoline Automation most of our systems are customised to adapt to the shifting needs of our clients. Our clients know we are with them every step of the way, ensuring their systems can evolve as their business grows and many of our systems have been with our customers for decades.

The stakes are high, but so is the potential. The UK’s manufacturing sector is a key contributor to the economy. For it to thrive, we must lean into technological advancements and educate the industry on the tangible benefits automation brings. Government initiatives and advocacy groups like Automate UK are working hard to create a supportive environment. But as industry players, we all have a role to play—and we need to demonstrate the full potential of automation and robotics and their power to transform operations and secure a robust future for UK manufacturing.

At Endoline Automation, we’re dedicated to more than just delivering cutting-edge end-of-line packaging solutions. We’re committed to being part of the movement that repositions the UK as a leader in manufacturing innovation. Together, we can build on the successes of 2024 and ensure a thriving and competitive manufacturing sector in 2025 and beyond.

Andrew Yates, Managing Director, Endoline Automation